Toyota - Land Cruiser - Parts Catalogue - 1996 - 1996

Brought to you by BirfMark Version 1.00 -original version released 12/21/2010 Version 1.11 -released 03/16/2011 -added cover page -added 'Starter' section Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark IN−1 INTRODUCTION − HOW TO USE THIS MANUAL HOW TO USE THIS MANUAL IN00U−36 GENERAL INFORMATION 1. INDEX An INDEX is provided on the first page of each section to guide you to the item to be repaired. To assist you in finding your way through the manual, the section title and major heading are given at the top of every page. 2. PRECAUTION At the beginning of each section, a PRECAUTION is given that pertains to all repair operations contained in that section. Read these precautions before starting any repair task. 3. TROUBLESHOOTING TROUBLESHOOTING tables are included for each system to help you diagnose the problem and find the cause. The fundamentals of how to proceed with troubleshooting are described on page IN−18. Be sure to read this before performing troubleshooting. 4. PREPARATION Preparation lists the SST (Special Service Tools), recommended tools, equipment, lubricant and SSM (Special Service Materials) which should be prepared before beginning the operation and explains the purpose of each one. 5. REPAIR PROCEDURES Most repair operations begin with an overview illustration. It identifies the components and shows how the parts fit together. Example: Filler Cap Float Clevis Pin z Gasket Reservoir Boot z Grommet Slotted Spring Pin Clip 12 (120, 9) Clevis 15 (155, 11) Snap Ring Washer Piston Lock Nut Push Rod Cylinder N·m (kgf·cm, ft·lbf) : Specified torque z Non−reusable part N17080 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 1 Brought to you by BirfMark IN−2 INTRODUCTION − HOW TO USE THIS MANUAL The procedures are presented in a step−by−step format: S The illustration shows what to do and where to do it. S The task heading tells what to do. S The detailed text tells how to perform the task and gives other information such as specifications and warnings. Example: Task heading : what to do 21. CHECK PISTON STROKE OF OVERDRIVE BRAKE (a) Place SST and a dial indicator onto the overdrive brake piston as shown in the illustration. SST 09350−30020 (09350−06120) Illustration: what to do and where Set part No. Detailed text : Component part No. how to do task (b) Measure the stroke applying and releasing the compressed air (392  785 kPa, 4  8 kgf/cm 2 or 57  114 psi) as shown in the illustration. Piston stroke: 1.40  1.70 mm (0.0551  0.0669 in.) Specification This format provides the experienced technician with a FAST TRACK to the information needed. The upper case task heading can be read at a glance when necessary, and the text below it provides detailed information. Important specifications and warnings always stand out in bold type. 6. REFERENCES References have been kept to a minimum. However, when they are required you are given the page to refer to. 7. SPECIFICATIONS Specifications are presented in bold type throughout the text where needed. You never have to leave the procedure to look up your specifications. They are also found in Service Specifications section for quick reference. 8. CAUTIONS, NOTICES, HINTS: S CAUTIONS are presented in bold type, and indicate there is a possibility of injury to you or other people. S NOTICES are also presented in bold type, and indicate the possibility of damage to the components being repaired. S HINTS are separated from the text but do not appear in bold. They provide additional information to help you perform the repair efficiently. 9. SI UNIT The UNITS given in this manual are primarily expressed according to the SI UNIT (International System of Unit), and alternately expressed in the metric system and in the English System. Example: Torque: 30 N·m (310 kgf·cm, 22 ft·lbf) 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 2 Brought to you by BirfMark IN−2 INTRODUCTION − HOW TO USE THIS MANUAL The procedures are presented in a step−by−step format: S The illustration shows what to do and where to do it. S The task heading tells what to do. S The detailed text tells how to perform the task and gives other information such as specifications and warnings. Example: Task heading : what to do 21. CHECK PISTON STROKE OF OVERDRIVE BRAKE (a) Place SST and a dial indicator onto the overdrive brake piston as shown in the illustration. SST 09350−30020 (09350−06120) Illustration: what to do and where Set part No. Detailed text : Component part No. how to do task (b) Measure the stroke applying and releasing the compressed air (392  785 kPa, 4  8 kgf/cm 2 or 57  114 psi) as shown in the illustration. Piston stroke: 1.40  1.70 mm (0.0551  0.0669 in.) Specification This format provides the experienced technician with a FAST TRACK to the information needed. The upper case task heading can be read at a glance when necessary, and the text below it provides detailed information. Important specifications and warnings always stand out in bold type. 6. REFERENCES References have been kept to a minimum. However, when they are required you are given the page to refer to. 7. SPECIFICATIONS Specifications are presented in bold type throughout the text where needed. You never have to leave the procedure to look up your specifications. They are also found in Service Specifications section for quick reference. 8. CAUTIONS, NOTICES, HINTS: S CAUTIONS are presented in bold type, and indicate there is a possibility of injury to you or other people. S NOTICES are also presented in bold type, and indicate the possibility of damage to the components being repaired. S HINTS are separated from the text but do not appear in bold. They provide additional information to help you perform the repair efficiently. 9. SI UNIT The UNITS given in this manual are primarily expressed according to the SI UNIT (International System of Unit), and alternately expressed in the metric system and in the English System. Example: Torque: 30 N·m (310 kgf·cm, 22 ft·lbf) 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 2 Brought to you by BirfMark IN−3 INTRODUCTION − IDENTIFICATION INFORMATION IDENTIFICATION INFORMATION VEHICLE IDENTIFICATION AND ENGINE SERIAL NUMBER IN04P−14 1. VEHICLE IDENTIFICATION NUMBER The vehicle identification number is stamped on the vehicle identification number plate and the certification label, as shown in the illustration. A: Vehicle Identification Number Plate B: Certification Label A B Z04707 2. ENGINE SERIAL NUMBER The engine serial number is stamped on the engine block, as shown in the illustration. P03780 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 3 Brought to you by BirfMark IN−4 INTRODUCTION − REPAIR INSTRUCTIONS REPAIR INSTRUCTIONS GENERAL INFORMATION IN0CO−12 BASIC REPAIR HINT (a) Use fender, seat and floor covers to keep the vehicle clean and prevent damage. (b) During disassembly, keep parts in the appropriate order to facilitate reassembly. (c) FI1066 (d) (e) (f) Seal Lock Adhesive Z11554 Installation and removal of battery terminal: (1) Before performing electrical work, disconnect the negative (−) terminal cable from the battery. (2) If it is necessary to disconnect the battery for inspection or repair, first disconnect the negative (−) terminal cable. (3) When disconnecting the terminal cable, to prevent damage to battery terminal, loosen the cable nut and raise the cable straight up without twisting or prying it. (4) Clean the battery terminals and cable ends with a clean shop rag. Do not scrape them with a file or other abrasive objects. (5) Install the cable ends to the battery terminals after loosening the nut, and tighten the nut after installation. Do not use a hammer to tap the cable ends onto the terminals. (6) Be sure the cover for the positive (+) terminal is properly in place. Check hose and wiring connectors to make sure that they are connected securely and correctly. Non−reusable parts (1) Always replace cotter pins, gaskets, O−rings, oil seals, etc. with new ones. (2) Non−reusable parts are indicated in the component illustrations by the ”z” symbol. Precoated parts Precoated parts are bolts, nuts, etc. that are coated with a seal lock adhesive at the factory. (1) If a precoated part is retightened, loosened or caused to move in any way, it must be recoated with the specified adhesive. (2) When reusing precoated parts, clean off the old adhesive and dry with compressed air. Then apply the specified seal lock adhesive to the bolt, nut or threads. 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 4 Brought to you by BirfMark IN−5 INTRODUCTION − REPAIR INSTRUCTIONS (3) (g) (h) (i) (j) Medium Current Fuse and High Current Fuse Equal Amperage Rating Precoated parts are indicated in the component illustrations by the ”L” symbol. When necessary, use a sealer on gaskets to prevent leaks. Carefully observe all specifications for bolt tightening torques. Always use a torque wrench. 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 in Preparation section in this manual. When replacing fuses, be sure the new fuse has the correct amperage rating. DO NOT exceed the rating or use one with a lower rating. BE1367 Illustration ~ ~ ~ ~ ~ iJ o~ Symbol Part Name ~ <> BE5594 FUSE MEDIUM CURRENT FUSE M−FUSE HIGH CURRENT FUSE H−FUSE FUSIBLE LINK FL CIRCUIT BREAKER CB IN0366 ~ BE5596 FUSE IN0365 ~ BE5595 Abbreviation IN0367 ~ BE5597 IN0367 BE5598 SN0368 V00076 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 5 Brought to you by BirfMark IN−6 INTRODUCTION (k) (l) WRONG − REPAIR INSTRUCTIONS Care must be taken when jacking up and supporting the vehicle. Be sure to lift and support the vehicle at the proper locations (See page IN−8). S Cancel the parking brake on the level place and shift the transmission in Neutral (or N position). S When jacking up the front wheels of the vehicle at first place stoppers behind the rear wheels. S When jacking up the rear wheels of the vehicle at first place stoppers before the front wheels. S When either the front or rear wheels only should be jacked up, set rigid racks and place stoppers in front and behind the other wheels on the ground. S After the vehicle is jacked up, be sure to support it on rigid racks . It is extremely dangerous to do any work on a vehicle raised on a jack alone, even for a small job that can be finished quickly. Observe the following precautions to avoid damage to the following parts: (1) Do not open the cover or case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) (2) To disconnect vacuum hoses, pull off the end, not the middle of the hose. (3) To pull apart electrical connectors, pull on the connector itself, not the wires. Be careful not to drop electrical components, such as sensors or relays. If they are dropped on a hard floor, they should be replaced and not reused. When steam cleaning an engine, protect the electronic components, air filter and emission−related components from water. Never use an impact wrench to remove or install temperature switches or temperature sensors. CORRECT IN0253 WRONG CORRECT (4) (5) IN0252 (6) 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 6 Brought to you by BirfMark IN−7 INTRODUCTION − (7) (8) (m) Example (n) IN0002 REPAIR INSTRUCTIONS When checking continuity at the wire connector, insert the tester probe carefully to prevent terminals from bending. When using a vacuum gauge, never force the hose onto a connector that is too large. Use a step−down adapter for adjustment. Once the hose has been stretched, it may leak air. Installation and removal of vacuum hose: (1) When disconnecting vacuum hoses, use tags to identify how they should be reconnected to. (2) After completing a job, double check that the vacuum hoses are properly connected. A label under the hood shows the proper layout. Unless otherwise stated, all resistance is measured at an ambient temperature of 20°C (68°F). Because the resistance may be outside specifications if measured at high temperatures immediately after the vehicle has been running, measurement should be made when the engine has cooled down. 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 7 Brought to you by BirfMark IN−8 INTRODUCTION − REPAIR INSTRUCTIONS IN0H2−01 VEHICLE LIFT AND SUPPORT LOCATIONS Front JACK POSITION Front ........................................ Under front differential Rear ......................................... Under rear differential SCREW TYPE JACK POSITION SUPPORT POSITION Safety stand .......................................................................... 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 o ~ Z00796 Brought to you by BirfMark IN−9 INTRODUCTION − FOR ALL OF VEHICLES FOR ALL OF VEHICLES PRECAUTION 1. (a) Negative Cable BO4111 (b) IN0IO−01 FOR VEHICLES EQUIPPED WITH SRS AIRBAG AND SEAT BELT PRETENSIONER The LAND CRUISER is equipped with an SRS (Supplemental Restraint System), such as the driver airbag and front passenger airbag assembly. Failure to carry out service operations in the correct sequence could cause the supplemental restraint system to unexpectedly deploy during servicing, possibly leading to a serious accident. Further, if a mistake is made in servicing the supplemental restraint system, it is possible the SRS may fail to operate when required. Before servicing (including removal or installation of parts, inspection or replacement), be sure to read the following items carefully, then follow the correct procedure described in this manual. GENERAL NOTICE (1) Malfunction symptoms of the supplemental restraint system are difficult to confirm, so the diagnostic trouble codes become the most important source of information when troubleshooting. When troubleshooting the supplemental restraint system, always inspect the diagnostic trouble codes before disconnecting the battery (See page DI−240). (2) Work must be started after 90 seconds from the time the ignition switch is turned to the ”LOCK” position and the negative (−) terminal cable is disconnected from the battery. (The supplemental restraint system is equipped with a back−up power source so that if work is started within 90 seconds of disconnecting the negative (−) terminal cable from the battery, the SRS may deploy.) When the negative (−) terminal cable is disconnected from the battery, memory of the clock and audio systems will be cancelled. So before starting work, make a record of the contents memorized by the each memory system. Then when work is finished, reset the clock and audio systems as before. To avoid erasing the memory of each memory system, never use a back−up power supply from another battery. 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 9 Brought to you by BirfMark IN−10 INTRODUCTION − FOR ALL OF VEHICLES (3) Even in cases of a minor collision where the SRS does not deploy, the steering wheel pad (See page RS−9) and front passenger airbag assembly (See page RS−23) should be inspected. (4) Never use SRS parts from another vehicle. When replacing parts, replace them with new parts. (5) Before repairs, remove the airbag sensor if shocks are likely to be applied to the sensor during repairs. (6) Never disassemble and repair the airbag sensor assembly, steering wheel pad or front passenger airbag assembly in order to reuse them. (7) If the airbag sensor assembly, steering wheel pad or front passenger airbag assembly have been dropped, or if there are cracks, dents or other defects in the case, bracket or connector, replace them with new ones. (8) Do not directly expose the airbag sensor assembly, steering wheel pad or front passenger airbag assembly to hot air or flames. (9) Use a volt/ohmmeter with high impedance (10 kΩ/V minimum) for troubleshooting of the electrical circuit. (10) Information labels are attached to the periphery of the SRS components. Follow the instructions on the notices. (11) After work on the supplemental restraint system is completed, check the SRS warning light (See page DI−240). (c) Red Mark SPIRAL CABLE (in Combination Switch) The steering wheel must be fitted correctly to the steering column with the spiral cable at the neutral position, otherwise cable disconnection and other troubles may result. Refer to SR−19 of this manual concerning correct steering wheel installation. ROOJll 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 10 Brought to you by BirfMark IN−11 INTRODUCTION (d) Example: − FOR ALL OF VEHICLES STEERING WHEEL PAD (with Airbag) (1) When removing the steering wheel pad or handling a new steering wheel pad, it should be placed with the pad top surface facing up. Storing the pad with its metallic surface facing upward may lead to a serious accident if the airbag inflates for some reason. In addition do not store a steering wheel pad on top of another one. (2) Never measure the resistance of the airbag squib. (This may cause the airbag to deploy, which is very dangerous.) (3) Grease should not be applied to the steering wheel pad and the pad should not be cleaned with detergents of any kind. (4) Store the steering wheel pad where the ambient temperature remains below 93°C (200°F), without high humidity and away from electrical noise. (5) When using electric welding, first disconnect the airbag connector (yellow color and 2 pins) under the steering column near the combination switch connector before starting work. (6) When disposing of a vehicle or the steering wheel pad alone, the airbag should be deployed using an SST before disposal (See page RS−11). Perform the operation in a safe place away from electrical noise. CORRECT WRONG x N01560 Z13953 Example: R05643 R06953 R06952 Z13950 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 11 Brought to you by BirfMark IN−12 INTRODUCTION (e) Example: CORRECT o − FOR ALL OF VEHICLES FRONT PASSENGER AIRBAG ASSEMBLY (1) Always store a removed or new front passenger airbag assembly with the airbag deployment direction facing up. Storing the airbag assembly with the airbag deployment direction facing down could cause a serious accident if the airbag inflates. (2) Never measure the resistance of the airbag squib. (This may cause the airbag to deploy, which is very dangerous.) (3) Grease should not be applied to the front passenger airbag assembly and the airbag door should not be cleaned with detergents of any kind. (4) Store the airbag assembly where the ambient temperature remains below 93°C (200°F), without high humidity and away from electrical noise. (5) When using electric welding, first disconnect the airbag connector (yellow color and 2 pins) installed on the assembly before starting work. (6) When disposing of a vehicle or the airbag assembly alone, the airbag should be deployed using an SST before disposal (See page RS−25). Perform the operation in a safe place away from electrical noise. WRONG R08766 Z13952 Example: R05648 R05649 R06952 Z13951 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 12 Brought to you by BirfMark IN−13 INTRODUCTION (f) (g) − FOR ALL OF VEHICLES AIRBAG SENSOR ASSEMBLY The connectors to the airbag sensor assembly should be connected or disconnected with the sensor mounted on the floor. If the connectors are connected or disconnected while the airbag sensor assembly is not mounted to the floor, it could cause undesired ignition of the supplemental restraint system. WIRE HARNESS AND CONNECTOR The SRS wire harness is integrated with the cowl wire harness assembly and floor wire harness assembly. The wires for the SRS wire harness are encased in a yellow corrugated tube. All the connectors for the system are also a standard yellow color. If the SRS wire harness becomes disconnected or the connector becomes broken due to an accident, etc., repair or replace it as shown on page RS−37. 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 13 Brought to you by BirfMark IN−14 INTRODUCTION 2. S S − FOR ALL OF VEHICLES WHEN TOWING FULL−TIME 4WD VEHICLES Use one of the methods shown below to tow the vehicle. If the vehicle has trouble in the chassis and drive train, use method 1 (flat bed truck). ~ ~ Towing Method Parking Brake Transmission Shift Lever Position Transfer Shift Lever Position (w/o ASS) Center Differential Lock Switch Center Differential CD Flat Sed Truck IN0309 @ Wheel Lift Type Truck with Dollies Applied II Range II H Position OFF FREE (Normal) Driving l I N II Range II N Position OFF t lip II ~ ii-;~ @ Towing with Rope L ~ Released /I IN0312 HINT: Do not use any towing methods other than those shown above. For example, the towing method shown below is dangerous, so do not use it. NO ~ During towing with this towing method, there is a danger of the drive train heating up and causing breakdown, or of the front wheels flying off the dolly. IN0313 \108127 V08127 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 14 Brought to you by BirfMark IN−15 INTRODUCTION − FOR ALL OF VEHICLES 3. FOR VEHICLES EQUIPPED WITH A CATALYTIC CONVERTER CAUTION: If large amount of unburned gasoline flows into the converter, it may overheat and create a fire hazard. To prevent this, observe the following precautions and explain them to your customer. (a) Use only unleaded gasoline. (b) Avoid prolonged idling. Avoid running the engine at idle speed for more than 20 minutes. (c) Avoid spark jump test. (1) Perform spark jump test only when absolutely necessary. Perform this test as rapidly as possible. (2) While testing, never race the engine. (d) Avoid prolonged engine compression measurement. Engine compression tests must be done as rapidly as possible. (e) Do not run engine when fuel tank is nearly empty. This may cause the engine to misfire and create an extra load on the converter. (f) Avoid coasting with ignition turned off. (g) Do not dispose of used catalyst along with parts contaminated with gasoline or oil. 4. IF VEHICLE IS EQUIPPED WITH MOBILE COMMUNICATION SYSTEM For vehicles with mobile communication systems such as two−way radios and cellular telephones, observe the following precautions. (1) Install the antenna as far as possible away from the ECU and sensors of the vehicle’s electronic system. (2) Install the antenna feeder at least 20 cm (7.87 in.) away from the ECU and sensors of the vehicle’s electronic systems. For details about ECU and sensors locations, refer to the section on the applicable component. (3) Avoid winding the antenna feeder together with other wiring as much as possible, and also avoid running the antenna feeder parallel with other wire harnesses. (4) Check that the antenna and feeder are correctly adjusted. (5) Do not install powerful mobile communications system. 5. FOR USING OBD II SCAN TOOL OR TOYOTA HAND−HELD TESTER CAUTION: Observe the following items for safety reasons: S Before using the OBD II scan tool or TOYOTA hand−held tester, the OBD II scan tool’s instruction book or TOYOTA hand−held tester’s operator manual should be read thoroughly. S Be sure to route all cables securely when driving with the OBD II scan tool or TOYOTA hand− held tester connected to the vehicle. (i.e. Keep cables away from feet, pedals, steering wheel and shift lever.) S Two persons are required when test driving with the OBD II scan tool or TOYOTA hand−held tester, one person to drive the vehicle and the other person to operate the OBD II scan tool or TOYOTA hand−held tester. 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 15 Brought to you by BirfMark IN−16 INTRODUCTION − FOR ALL OF VEHICLES 6. ANTI-THEFT SYSTEM Cassette Tape Slot Cover BE2826 FOR VEHICLES WITH AN AUDIO SYSTEM WITH BUILT−IN ANTI−THEFT SYSTEM Audio System displaying the sign ANTI−THEFT SYSTEM shown on the left has a built−in anti−theft system which makes the audio system soundless if stolen. If the power source for the audio system is cut even once, the anti0theft system operates so that even if the power source is reconnected, the audio system will not produce any sound unless the ID number selected by the customer is input again. Accordingly, when performing repairs on vehicles equipped with this system, before disconnecting the battery terminals or removing the audio system the customer should be asked for the ID number afterwards, or else a request made to the customer to input the ID number. For the method to input the ID number or cancel the anti−theft system, refer to the Owner’s Manual. 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 16 Brought to you by BirfMark INTRODUCTION − HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS IN−17 HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS IN04S−30 GENERAL INFORMATION A large number of ECU controlled systems are used in the LAND CRUISER. In general, the ECU controlled system is considered to be a very intricate system requiring a high level of technical knowledge and expert skill to troubleshoot. However, the fact is that if you proceed to inspect the circuits one by one, troubleshooting of these systems is not complex. If you have adequate understanding of the system and a basic knowledge of electricity, accurate diagnosis and necessary repair can be performed to locate and fix the problem. This manual is designed through emphasis of the above standpoint to help service technicians perform accurate and effective troubleshooting, and is compiled for the following major ECU controlled systems: The troubleshooting procedure and how to make use of it are described on the following pages. System Page 1. Engine DI−1 2. Automatic Transmission DI−129 3. Anti−Lock Brake System DI−188 4. Supplemental Restraint System DI−238 5. Cruise Control System DI−284 FOR USING OBD II SCAN TOOL OR TOYOTA HAND−HELD TESTER S Before using the scan tool or tester, the scan tool’s instruction book or tester’s operator manual should be read thoroughly. S If the scan tool or tester cannot communicate with ECU controlled systems when you have connected the cable of the scan tool or tester to DLC3, turned the ignition switch ON and operated the scan tool, there is a problem on the vehicle side or tool side. (1) If communication is normal when the tool is connected to another vehicle, inspect the diagnosis data link line (Busęline) or ECU power circuit of the vehicle. (2) If communication is still not possible when the tool is connected to another vehicle, the problem is probably in the tool itself, so perform the Self Test procedures outline in the Tester Operator’s Manual. 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 17 Brought to you by BirfMark IN−18 INTRODUCTION − HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS HOW TO PROCEED WITH TROUBLESHOOTING IN04T−19 Carry out troubleshooting in accordance with the procedure on the following page. Here, only the basic procedure is shown. Details are provided in Diagnostics section, showing the most effective methods for each circuit. Confirm the troubleshooting procedures first for the relevant circuit before beginning troubleshooting of that circuit. Vehicle Brought to Workshop 1 2 1 Ask the customer about the conditions and the environment when the problem occurred. Customer Problem Analysis Symptom Confirmation and Diagnostic Trouble Code Check 3 Symptom Simulation 2, 3 Confirm the symptoms and the problem conditions, and check the diagnostic trouble codes. (When the problem symptoms do not appear during confirmation, use the symptom simulation method described later on.) 4 Diagnostic Trouble Code Chart 5 6 Problem Symptoms Table Circuit Inspection or Parts Inspection 7 Repair 8 Confirmation Test End 4, 5, 6 Check the results obtained in Step 2, then confirm the inspection procedure for the system or the part which should be checked using the diagnostic trouble code chart or the problem symptoms table. 7 Check and repair the affected system or part in accordance with the instructions in Step 6. 8 After completing repairs, confirm that the problem has been eliminated. (If the problem is not reproduced, perform the confirmation test under the same conditions and in the same environment as when it occurred for the first time.) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark INTRODUCTION − HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS IN−19 1. CUSTOMER PROBLEM ANALYSIS In troubleshooting, the problem symptoms must be confirmed accurately and all preconceptions must be cleared away in order to give an accurate judgment. To ascertain just what the problem symptoms are, it is extremely important to ask the customer about the problem and the conditions at the time it occurred. Important Point in the Problem Analysis: The following 5 items are important points in the problem analysis. Past problems which are thought to be unrelated and the repair history, etc. may also help in some cases, so as much information as possible should be gathered and its relationship with the problem symptoms should be correctly ascertained for reference in troubleshooting. A customer problem analysis table is provided in Diagnostics section for each system for your use. Important Points in the Customer Problem Analysis D What −−−−− Vehicle model, system name D When −−−−− Date, time, occurrence frequency D Where −−−−− Road conditions D Under what conditions? −−−−− Running conditions, driving conditions, weather conditions D How did it happen? −−−−− Problem symptoms (Sample) Engine control system check sheet. CUSTOMER PROBLEM ANALYSIS CHECK ENGINE CONTROL SYSTEM Check Sheet Inspector’s Name Model and Model Year Driver’s Name Frame No. Data Vehicle Brought in Engine Model License No. Odometer Reading Problem Symptoms Customer’s Name Engine does not Start Engine does not crank Difficult to Start Engine cranks slowly Other Poor Idling Incorrect first idle Idling rpm is abnormal Rough idling Other Poor Drive ability Hesitation Knocking Engine Stall Soon after starting After accelerator pedal depressed After accelerator pedal released During A/C operation Shifting from N to D Other No initial combustion Back fire Other High ( Muffler explosion (after−fire) Others Data Problem Constant Sometimes ( times per 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 day/month) km miles No complete combustion rpm) Low ( Surging rpm) Brought to you by BirfMark IN−20 INTRODUCTION − HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS 2. SYMPTOM CONFIRMATION AND DIAGNOSTIC TROUBLE CODE CHECK The diagnostic system in the LAND CRUISER fulfills various functions. The first function is the Diagnostic Trouble Code Check in which a malfunction in the signal circuits to the ECU is stored in code in the ECU memory at the time of occurrence, to be output by the technician during troubleshooting. Another function is the Input Signal Check which checks if the signals from various switches are sent to the ECU correctly. By using these check functions, the problem areas can be narrowed down quickly and troubleshooting can be performed effectively. Diagnostic functions are incorporated in the following systems in the LAND CRUISER. Diagnostic Trouble Code Check Input Signal Check (Sensor Check) Diagnostic Test Mode (Active Test) 1. Engine f (with Check Mode) f f 2. Automatic Transmission f (with Check Mode) f f 3. Anti−Lock Brake System f f f 4. Supplemental Restraint System f f 5. Cruise Control System f f System In diagnostic trouble code check, it is very important to determine whether the problem indicated by the diagnostic trouble code is still occurring or occurred in the past but returned to normal at present. In addition, it must be checked in the problem symptom check whether the malfunction indicated by the diagnostic trouble code is directly related to the problem symptom or not. For this reason, the diagnostic trouble codes should be checked before and after the symptom confirmation to determine the current conditions, as shown in the table below. If this is not done, it may, depending on the case, result in unnecessary troubleshooting for normally operating systems, thus making it more difficult to locate the problem, or in repairs not pertinent to the problem. Therefore, always follow the procedure in correct order and perform the diagnostic trouble code check. DIAGNOSTIC TROUBLE CODE CHECK PROCEDURE Diagnostic Trouble Code Check (Make a note of and then clear) Diagnostic Trouble Code Display Confirmation of Symptoms Diagnostic Trouble Code Check Problem symptoms Same diagnostic trouble code is exist displayed Normal code is displayed Normal Code Display Problem Condition Problem is still occurring in the diagnostic circuit The problem is still occurring in a place other than in the diagnostic circuit (The diagnostic trouble code displayed first is either for a past problem or it is a secondary problem) No problem symptoms exist The problem occurred in the diagnostic circuit in the past Problem symptoms Normal code is exist displayed The problem is still occurring in a place other than in the diagnostic circuit No problem symptoms exist The problem occurred in a place other than in the diagnostic circuit in the past Normal code is displayed 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark INTRODUCTION − HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS IN−21 Taking into account the points on the previous page, a flow chart showing how to proceed with troubleshooting using the diagnostic trouble code check is shown below. This flow chart shows how to utilize the diagnostic trouble code check effectively, then by carefully checking the results, indicates how to proceed either to diagnostic trouble code troubleshooting or to troubleshooting of problem symptoms table. Diagnostic trouble code check Making a note of and clearing of the diagnostic trouble codes displayed Symptom confirmation Problem symptoms exist No problem symptoms exist Simulation test using the symptom simulation methods Diagnostic trouble code check D Diagnostic trouble code displayed D Problem symptoms exist D Normal code displayed D Problem symptoms exist Troubleshooting of problem indicated by diagnostic trouble code Troubleshooting of each problem symptom 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 D Normal code displayed D No problem symptoms exist System Normal If a diagnostic trouble code was displayed in the initial diagnostic trouble code check, it indicates that the trouble may have occurred in a wire harness or connector in that circuit in the past. Therefore, check the wire harness and connectors (See page IN−28). Brought to you by BirfMark IN−22 INTRODUCTION − HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS 3. SYMPTOM SIMULATION The most difficult case in troubleshooting is when there are no problem symptoms occurring. In such cases, a thorough customer problem analysis must be carried out, then simulate the same or similar conditions and environment in which the problem occurred in the customer’s vehicle. No matter how much experience a technician has, or how skilled he may be, if he proceeds to troubleshoot without confirming the problem symptoms he will tend to overlook something important in the repair operation and make a wrong guess somewhere, which will only lead to a standstill. For example, for a problem which only occurs when the engine is cold, or for a problem which occurs due to vibration caused by the road during driving, etc., the problem can never be determined so long as the symptoms are confirmed with the engine hot condition or the vehicle at a standstill. Since vibration, heat or water penetration (moisture) is likely cause for problem which is difficult to reproduce, the symptom simulation tests introduced here are effective measures in that the external causes are applied to the vehicle in a stopped condition. Important Points in the Symptom Simulation Test: In the symptom simulation test, the problem symptoms should of course be confirmed, but the problem area or parts must also be found out. To do this, narrow down the possible problem circuits according to the symptoms before starting this test and connect a tester beforehand. After that, carry out the symptom simulation test, judging whether the circuit being tested is defective or normal and also confirming the problem symptoms at the same time. Refer to the problem symptoms table for each system to narrow down the possible causes of the symptom. 1 VIBRATION METHOD: When vibration seems to be the major cause. CONNECTORS Slightly shake the connector vertically and horizontally. Shake Slightly WIRE HARNESS Slightly shake the wire harness vertically and horizontally. The connector joint, fulcrum of the vibration, and body through portion are the major areas to be checked thoroughly. Swing Slightly FI2331 FI2332 PARTS AND SENSOR Vibrate Slightly Apply slight vibration with a finger to the part of the sensor considered to be the problem cause and check that the malfunction occurs. HINT: Applying strong vibration to relays may result in open relays. FI2330 V07268 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark INTRODUCTION 2 − HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS IN−23 HEAT METHOD: When the problem seems to occur when the suspect area is heated. Heat the component that is the likely cause of the malfunction with a hair dryer or similar object. Check to see if the malfunction occurs. M a l f u n ction NOTICE: (1) Do not heat to more than 60°C (140°F). (Temperature is limited not to damage the components.) (2) Do not apply heat directly to parts in the ECU. FI2334 3 WATER SPRINKLING METHOD: When the malfunction seems to occur on a rainy day or in a high−humidity condition. Sprinkle water onto the vehicle and check to see if the malfunction occurs. NOTICE: (1) Never sprinkle water directly into the engine compartment, but indirectly change the temperature and humidity by applying water spray onto the radiator front surface. (2) Never apply water directly onto the electronic components. HINT: If a vehicle is subject to water leakage, the leaked water may contaminate the ECU. When testing a vehicle with a water leakage problem, special caution must be taken. 4 FI6649 OTHER: When a malfunction seems to occur when electrical load is excessive. Turn on all electrical loads including the heater blower, head lights, rear window defogger, etc. and check to see if the malfunction occurs. ON B02389 B02390 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark IN−24 INTRODUCTION − HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS 4. DIAGNOSTIC TROUBLE CODE CHART The inspection procedure is shown in the table below. This table permits efficient and accurate troubleshooting using the diagnostic trouble codes displayed in the diagnostic trouble code check. Proceed with troubleshooting in accordance with the inspection procedure given in the diagnostic chart corresponding to the diagnostic trouble codes displayed. The engine diagnostic trouble code chart is shown below as an example. D DTC No. Indicates the diagnostic trouble code. D Page or Instructions Indicates the page where the inspection procedure for each circuit is to be found, or gives instructions for checking and repairs. D Trouble Area Indicates the suspect area of the problem. D Detection Item Indicates the system of the problem or contents of the problem. DIAGNOSTIC TROUBLE CODE CHART HINT: Parameters listed in the chart may not be exactly the same as your reading due to the type of instrument or other factors. If a malfunction code is displayed during the DTC check mode, check the circuit for the code listed in the table below. For details of each code, turn to the page referred to under the ”See page” for the respective ”DTC No.” in the DTC chart. SAE CONTROLLED DTC No. (See page) Detection Item Trouble Area P0100 (DI−24) Mass Air Flow Circuit Malfunction D Open or short in mass air flow meter circuit D Mass air flow meter D ECM P0101 (DI−28) Mass Air Flow Circuit Range/ Performance Problem D Mass air flow meter P0110 (DI−29) Intake Air Temp. Circuit Malfunction D Open or short in intake air temp. sensor circuit D Intake air temp. sensor D ECM P0115 (DI−33) Engine Coolant Temp. Circuit Malfunction D Open or short in engine coolant temp. sensor circuit D Engine coolant temp. sensor D ECM P0116 (DI−37) Engine Coolant Temp. Circuit Range/ Performance Problem D Engine coolant temp. sensor D Cooling system Throttle/ Pedal Position Sensor/Switch ”A” Circuit Malfunction D Open or short in throttle position sensor circuit D Throttle position sensor D ECM Throttle/ Pedal Position Sensor/ Switch ”A” Circuit Range / Performance Problem D Throttle position sensor 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 MIL* Memory Brought to you by BirfMark INTRODUCTION − IN−25 HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS 5. PROBLEM SYMPTOMS TABLE The suspected circuits or parts for each problem symptom are shown in the table below. Use this table to troubleshoot the problem when a ”Normal” code is displayed in the diagnostic trouble code check but the problem is still occurring. Numbers in the table indicate the inspection order in which the circuits or parts should be checked. HINT: When the problem is not detected by the diagnostic system even though the problem symptom is present, it is considered that the problem is occurring outside the detection range of the diagnostic system, or that the problem is occurring in a system other than the diagnostic system. D Page Indicates the page where the flow chart for each circuit is located. D Circuit Inspection, Inspection Order Indicates the circuit which needs to be checked for each problem symptom. Check in the order indicated by the numbers. D Problem Symptom D Circuit or Part Name Indicates the circuit or part which needs to be checked. PROBLEM SYMPTOMS TABLE Symptom Suspected Area See page Engine does not crank (Does not start) 1. Starter and starter relay ST−2 ST−17 No initial combustion (Does not start) 1. ECM power source circuit 2. Fuel pump control circuit 3. ECM DI−147 DI−151 IN−29 No complete combustion (Does not start) 1. Fuel pump control circuit DI−151 Engine cranks normally (Difficult to start) 1. Starter signal circuit 2. Fuel pump control circuit 3. Compression DI−144 DI−151 EM−3 Cold engine (Difficult to start) 1. Starter signal circuit 2. Fuel pump control circuit DI−144 DI−151 Hot engine 1. Starter signal circuit 2. Fuel pump control circuit DI−144 DI−151 High engine idle speed (Poor idling) 1. A/C signal circuit (Compressor circuit) 2. ECM power source circuit AC−88 idling) 1. A/C signal circuit 2. Fuel pump control circuit 1. Compression 2. Fuel pump control circuit 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark IN−26 INTRODUCTION − HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS 6. CIRCUIT INSPECTION How to read and use each page is shown below. D Diagnostic Trouble Code No. and Detection Item D Circuit Description The major role and operation, etc. of the circuit and its component parts are explained. DTC Knock Sensor 1 Circuit Malfunction P0325 CIRCUIT DESCRIPTION Knock sensor is fitted to the cylinder block to detect engine knocking. This sensor contains a piezoelectric element which generates a voltage when it becomes deformed, which occurs when the cylinder block vibrates due to knocking. If engine knocking occurs, ignition timing is retarded to suppress it. DTC No. P0325 DTC Detection Condition Trouble Area No knock sensor 1 signal to ECM with engine speed, 1,200 rpm or more. D Open or short in knock sensor1 circuit D Knock sensor 1 (looseness) D ECM If the ECM detects the above diagnosis conditions, it operates the fall safe function in which the corrective retard angle value is set to the maximum value. D Indicates the diagnostic trouble code, diagnostic trouble code set parameter and suspect area of the problem. WIRING DIAGRAM ECM Knock Sensor 1 GR 12 KNK E6 E1 D Wiring Diagram This shows a wiring diagram of the circuit. Use this diagram together with ELECTRICAL WIRING DIAGRAM to thoroughly understand the circuit. Wire colors are indicated by an alphabetical code. B = Black, L = Blue, R = Red, BR = Brown, LG = Light Green, V = Violet, G = Green, O = Orange, W = White, GR = Gray, P = Pink, Y = Yellow, SB = Sky Blue The first letter indicates the basic wire color and the second letter indicates the color of the stripe. V08423 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark INTRODUCTION − HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS D Indicates the position of the ignition switch during the check. ON LOCK Ignition Switch LOCK (OFF) (2) START Ignition Switch ON ACC (2) Ignition Switch START Ignition Switch ACC IN−27 D Inspection Procedure Use the inspection procedure to determine if the circuit is normal or abnormal, and, if it is abnormal, use it to determine whether the problem is located in the sensors, actuators, wire harness or ECU. INSPECTION PROCEDURE 1 Check continuity between terminal KNK of ECM connector and body ground. PREPARATION: (a) Remove the glove compartment (See page SF−68). (b) Disconnect the E6 connector from the ECM. LOCK KNK CHECK: Measure the resistance between terminal KNK of the ECM connector and body ground. E6 Connector OK: Resistance: 1 MΩ or higher AB0117 A00265 A00255 OK Go to step 3. NG 2 Check knock sensor (See page SF−61). OK Replace knock sensor. D Indicates the place to check the voltage or resistance. D Indicates the connector position to checked, from the front or back side. ~ ~ Wire Harness Check from the connector front side. (without harness) In this case, care must be taken not to bend the terminals. Check from the connector back side. (with harness) D Indicates the condition of the connector of ECU during the check. KNK KNK E6 Connector E6 Connector Connector being checked is connected. Connector being checked is disconnected. V08425 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark IN−28 INTRODUCTION − HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS HOW TO USE THE DIAGNOSTIC CHART AND INSPECTION PROCEDURE 1. FI0046 FI0047 FI0048 IN05X−13 CONNECTOR CONNECTION AND TERMINAL INSPECTION S For troubleshooting, diagnostic trouble code charts or problem symptom table are provided for each circuit with detailed inspection procedures on the following pages. S When all the component parts, wire harnesses and connectors of each circuit except the ECU are found to be normal in troubleshooting, then it is determined that the problem is in the ECU. Accordingly, if diagnosis is performed without the problem symptoms occurring, refer to Step 8 to replace the ECU. So always confirm that the problem symptoms are occurring, or proceed with inspection while using the symptom simulation method. S The instructions ”Check wire harness and connector” and ”Check and replace ECU” which appear in the inspection procedure, are common and applicable to all diagnostic trouble codes. Follow the procedure outlined below whenever these instructions appear. OPEN CIRCUIT: This could be due to a disconnected wire harness, faulty contact in the connector, a connector terminal pulled out, etc. HINT: S It is rarely the case that a wire is broken in the middle of it. Most cases occur at the connector. In particular, carefully check the connectors of sensors and actuators S Faulty contact could be due to rusting of the connector terminals, to foreign materials entering terminals or a deformation of connector terminals. Simply disconnecting and reconnecting the connectors once changes the condition of the connection and may result in a return to normal operation. Therefore, in troubleshooting, if no abnormality is found in the wire harness and connector check, but the problem disappears after the check, then the cause is considered to be in the wire harness or connectors. SHORT CIRCUIT: This could be due to a contact between wire harness and the body ground or to a short circuit occurred inside the switch, etc. HINT: When there is a short circuit between the wire harness and body ground, check thoroughly whether the wire harness is caught in the body or is clamped properly. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark INTRODUCTION − HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS IN−29 2. CONNECTOR HANDLING When inserting tester probes into a connector, insert them from the rear of the connector. When necessary, use mini test leads. For water resistant connectors which cannot be accessed from behind, take good care not to deform the connector terminals. FI7187 Sensor Side ECU Side 3. (a) CONTINUITY CHECK (OPEN CIRCUIT CHECK) Disconnect the connectors at both ECU and sensor sides. (b) Measure the resistance between the applicable terminals of the connectors. Resistance: 1 Ω or less IN0379 ECU Side Sensor Side HINT: Measure the resistance while lightly shaking the wire harness vertically and horizontally. c:::::J o 0 IN0378 4. (a) (b) ECU Side Sensor Side c::=J o 0 IN0380 HINT: Measure the resistance while lightly shaking the wire harness vertically and horizontally. 5. (a) (b) Pull Lightly Looseness of Crimping IN0381 RESISTANCE CHECK (SHORT CIRCUIT CHECK) Disconnect the connectors on both ends. Measure the resistance between the applicable terminals of the connectors and body ground. Be sure to carry out this check on the connectors on both ends. Resistance: 1 MΩ or higher (c) VISUAL CHECK AND CONTACT PRESSURE CHECK Disconnect the connectors at both ends. Check for rust or foreign material, etc. in the terminals of the connectors. Check crimped portions for looseness or damage and check that the terminals are secured in lock portion. HINT: The terminals should not come out when pulled lightly from the back. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark IN−30 INTRODUCTION − HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS (d) Prepare a test male terminal and insert it in the female terminal, then pull it out. NOTICE: When testing a gold−plated female terminal, always use a gold−plated male terminal. HINT: When the test terminal is pulled out more easily than others, there may be poor contact in that section. Fig. 1 Sensor ECU C B 1 2 OPEN 1 1 2 2 A 1 2 6. CHECK OPEN CIRCUIT For the open circuit in the wire harness in Fig. 1, perform ”(a) Continuity Check” or ”(b) Voltage Check” to locate the section. BE4063 Z17004 (a) Fig. 2 ECU C 1 2 Sensor B A 1 2 1 2 Z17005 Check the continuity. (1) Disconnect connectors ”A” and ”C” and measure the resistance between them. In the case of Fig. 2: Between terminal 1 of connector ”A” and terminal 1 of connector ”C” → No continuity (open) Between terminal 2 of connector ”A” and terminal 2 of connector ”C” → Continuity Therefore, it is found out that there is an open circuit between terminal 1 of connector ”A” and terminal 1 of connector ”C”. (2) Fig. 3 DO ECU Sensor C 1 2 B2 1 2 1 B1 1 2 A 1 2 B04722 Disconnect connector ”B” and measure the resistance between the connectors. In the case of Fig. 3: Between terminal 1 of connector ”A” and terminal 1 of connector ”B1” → Continuity Between terminal 1 of connector ”B2” and terminal 1 of connector ”C” → No continuity (open) Therefore, it is found out that there is an open circuit between terminal 1 of connector ”B2” and terminal 1 of connector ”C”. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark INTRODUCTION − HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS IN−31 (b) Fig. 4 Sensor 5V A C 5V B 1 1 1 2 2 2 0V BE4066 5V Z17007 7. CHECK SHORT CIRCUIT If the wire harness is ground shorted as in Fig. 5, locate the section by conducting a ”continuity check with ground”. Fig. 5 C SHORT B 1 1 2 2 Check the voltage. In a circuit in which voltage is applied (to the ECU connector terminal), an open circuit can be checked for by conducting a voltage check. As shown in Fig. 4, with each connector still connected, measure the voltage between body ground and terminal 1 of connector ”A” at the ECU 5V output terminal, terminal 1 of connector ”B”, and terminal 1 of connector ”C”, in that order. If the results are: 5V: Between Terminal 1 of connector ”A” and Body Ground 5V: Between Terminal 1 of connector ”B” and Body Ground 0V: Between Terminal 1 of connector ”C” and Body Ground Then it is found out that there is an open circuit in the wire harness between terminal 1 of ”B” and terminal 1 of ”C”. A 1 2 BE4067 Z17008 Fig. 6 Sensor C 1 2 B 1 2 BE4068 A 1 2 ECU Z17009 Check the continuity with ground. (1) Disconnect connectors ”A” and ”C” and measure the resistance between terminal 1 and 2 of connector ”A” and body ground. In the case of Fig. 6: Between terminal 1 of connector ”A” and body ground → Continuity (short) Between terminal 2 of connector ”A” and body ground → No continuity Therefore, it is found out that there is a short circuit between terminal 1 of connector ”A” and terminal 1 of connector ”C”. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark IN−32 INTRODUCTION − HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS (2) Fig. 7 Sensor C 1 2 B2 1 2 B1 1 2 A 1 2 ECU Z17808 Disconnect connector ”B” and measure the resistance between terminal 1 of connector ”A” and body ground, and terminal 1 of connector ”B2” and body ground. In the case of Fig. 7: Between terminal 1 of connector ”A” and body ground → No continuity Between terminal 1 of connector ”B2” and body ground → Continuity (short) Therefore, it is found out that there is a short circuit between terminal 1 of connector ”B2” and terminal 1 of connector ”C”. 8. CHECK AND REPLACE ECU First check the ECU ground circuit. If it is faulty, repair it. If it is normal, the ECU could be faulty, so replace the ECU with a normal functioning one and check that the symptoms appear. (1) Measure the resistance between the ECU ground terminal and the body ground. Resistance: 1 Ω or less Example Ground o IN0383 (2) ECU Side D~~~D ~~~ Disconnect the ECU connector, check the ground terminals on the ECU side and the wire harness side for bend and check the contact pressure. Ground W/H Side Ground IN0384 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark IN−33 INTRODUCTION − TERMS TERMS IN04Q−07 ABBREVIATIONS USED IN THIS MANUAL Abbreviations Meaning ABS Anti−Lock Brake System AC Alternating Current ACC Accessory ACIS Acoustic Control Induction System ACSD Automatic Cold Start Device A.D.D. Automatic Disconnecting Differential A/F Air−Fuel Ratio AHC Active Height Control Suspension ALR Automatic Locking Retractor ALT Alternator AMP Amplifier ANT Antenna APPROX. Approximately A/T Automatic Transmission (Transaxle) ATF Automatic Transmission Fluid AUTO Automatic AUX Auxiliary AVG Average AVS Adaptive Variable Suspension BA Brake Assist BACS Boost Altitude Compensation System BAT Battery BDC Bottom Dead Center B/L Bi−Level B/S Bore−Stroke Ratio BTDC Before Top Dead Center BVSV Bimetallic Vacuum Switching Valve Calif. California CB Circuit Breaker CCo Catalytic Converter For Oxidation CD Compact Disc CF Cornering Force CG Center Of Gravity CH Channel COMB. Combination CPE Coupe CPS Combustion Pressure Sensor CPU Central Processing Unit CRS Child Restraint System CTR Center C/V Check Valve CV Control Valve 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 33 Brought to you by BirfMark IN−34 INTRODUCTION − TERMS CW Curb Weight DC Direct Current DEF Defogger DFL Deflector DIFF. Differential DIFF. LOCK Differential Lock D/INJ Direct Injection DLI Distributorless Ignition DOHC Double Over Head Cam DP Dash Pot DS Dead Soak DSP Digital Signal Processor EBD Electronic Brake Force Distribution ECAM Engine Control And Measurement System ECD Electronic Controlled Diesel ECDY Eddy Current Dynamometer ECU Electronic Control Unit ED Electro−Deposited Coating EDIC Electric Diesel Injection Control EDU Electronic Driving Unit EFI Electronic Fuel Injection E/G Engine EGR−VM Exhaust Gas Recirculation−Vacuum Modulator ELR Emergency Locking Retractor ENG Engine ESA Electronic Spark Advance ETCS Electronic Throttle Control System EVP Evaporator E−VRV Electric Vacuum Regulating Valve EXH Exhaust FE Fuel Economy FF Front−Engine Front−Wheel−Drive F/G Fuel Gage FIPG Formed In Place Gasket FL Fusible Link F/P Fuel Pump FPU Fuel Pressure Up Fr Front FR Front−Engine Rear−Wheel−Drive F/W Flywheel FW/D Flywheel Damper FWD Front−Wheel−Drive GAS Gasoline GSA Gear Shift Actuator GND Ground HAC 1996 LAND CRUISER (RM451U) High Altitude Compensator Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 34 Brought to you by BirfMark IN−35 INTRODUCTION − TERMS H/B Hatchback H−FUSE High Current Fuse HI High HID High Intensity Discharge (Head Lamp) HPU Hydraulic Power Unit HSG Housing HT Hard Top HWS Heated Windshield System IAC Idle Air Control IC Integrated circuit IDI Indirect Diesel Injection IFS Independent Front Suspension IG Ignition IIA Integrated Ignition Assembly IN Intake (Manifold, Valve) INT Intermittent I/P Instrument Panel IRS Independent Rear Suspension J/B Junction Block J/C Junction Connector KD Kick−Down LAN Local Area Network LB Liftback LCD Liquid Crystal Display LED Light Emitting Diode LH Left−Hand LHD Left−Hand Drive L/H/W Length, Height, Width LLC Long−Life Coolant LNG Liquified Natural Gas LO Low LPG Liquified Petroleum Gas LSD Limited Slip Differential LSP & PV Load Sensing Proportioning And Bypass Valve LSPV Load Sensing Proportioning Valve MAX. Maximum M−FUSE Medium Current Fuse MIC Microphone MIL Malfunction Indicator Lamp MIN. Minimum MP Multipurpose MPX Multiplex Communication System M/T Manual Transmission (Transaxle) MT Mount MTG Mounting N 1996 LAND CRUISER (RM451U) Neutral Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 35 Brought to you by BirfMark IN−36 INTRODUCTION − TERMS NA Natural Aspiration No. Number O/D Overdrive OEM Original Equipment Manufacturing OHC Overhead Camshaft OHV Overhead Valve OPT Option O/S Oversize P & BV Proportioning And Bypass Valve PCS Power Control System PCV Positive Crankcase Ventilation PKB Parking Brake PPS Progressive Power Steering PS Power Steering PTO Power Take−Off R&P Rack And Pinion R/B Relay Block RBS Recirculating Ball Type Steering R/F Reinforcement RFS Rigid Front Suspension RH Right−Hand RHD Right−Hand Drive RLY Relay ROM Read Only Memory Rr Rear RR Rear−Engine Rear−Wheel Drive RRS Rigid Rear Suspension RWD Rear−Wheel Drive SDN Sedan SEN Sensor SICS Starting Injection Control System SMT Sequential Manual Transmission SOC State Of Charge SOHC Single Overhead Camshaft SPEC Specification SPI Single Point Injection SRS Supplemental Restraint System SSM Special Service Materials SST Special Service Tools STD Standard STJ Cold−Start Fuel Injection SW Switch SYS System T/A Transaxle TACH Tachometer TBI 1996 LAND CRUISER (RM451U) Throttle Body Electronic Fuel Injection Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 36 Brought to you by BirfMark IN−37 INTRODUCTION − TERMS TC Turbocharger TCCS TOYOTA Computer−Controlled System TCV Timing Control Valve TDC Top Dead Center TEMP. Temperature TEMS TOYOTA Electronic Modulated Suspension TIS Total Information System For Vehicle Development T/M Transmission TMC TOYOTA Motor Corporation TMMK TOYOTA Motor Manufacturing Kentucky, Inc. TRAC Traction Control System TURBO Turbocharge U/D Underdrive U/S Undersize VCV Vacuum Control Valve VENT Ventilator VIN Vehicle Identification Number VPS Variable Power Steering VSC Vehicle Skid Control VSV Vacuum Switching Valve VTV Vacuum Transmitting Valve w/ With WGN Wagon W/H Wire Harness w/o Without 1st First 2nd Second 2WD Two Wheel Drive Vehicle (4x2) 4WD Four Wheel Drive Vehicle (4x4) 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 37 Brought to you by BirfMark IN−38 INTRODUCTION − TERMS IN0CI−02 GLOSSARY OF SAE AND TOYOTA TERMS This glossary lists all SAE−J1930 terms and abbreviations used in this manual in compliance with SAE recommendations, as well as their TOYOTA equivalents. SAE ABBREVIATIONS TOYOTA TERMS ( )−−ABBREVIATIONS SAE TERMS A/C Air Conditioning Air Conditioner ACL Air Cleaner Air Cleaner, A/CL AIR Secondary Air Injection Air Injection (AI) AP Accelerator Pedal B+ Battery Positive Voltage +B, Battery Voltage BARO Barometric Pressure HAC CAC Charge Air Cooler Intercooler CARB Carburetor Carburetor CFI Continuous Fuel Injection CKP Crankshaft Position Crank Angle CL Closed Loop Closed Loop CMP Camshaft Position Cam Angle CPP Clutch Pedal Position − CTOX Continuous Trap Oxidizer − CTP Closed Throttle Position LL ON, Idle ON DFI Direct Fuel Injection (Diesel) Direct Injection (DI) DI Distributor Ignition DLC1 DLC2 DLC3 Data Link Connector 1 Data Link Connector 2 Data Link Connector 3 1: Check Connector 2: Total Diagnosis Comunication Link (TDCL) 3: OBD II Diagnostic Connector DTC Diagnostic Trouble Code Diagnostic Code DTM Diagnostic Test Mode ECL Engine Control Level ECM Engine Control Module Engine ECU (Electronic Control Unit) ECT Engine Coolant Temperature Coolant Temperature, Water Temperature (THW) EEPROM Electrically Erasable Programmable Read Only Memory Electrically Erasable Programmable Read Only Memory (EEPROM), Erasable Programmable Read Only Memory (EPROM) EFE Early Fuel Evaporation Cold Mixture Heater (CMH), Heat Control Valve (HCV) EGR Exhaust Gas Recirculation Exhaust Gas Recirculation (EGR) EI Electronic Ignition TOYOTA Distributorless Ignition (TDI) EM Engine Modification Engine Modification (EM) EPROM Erasable Programmable Read Only Memory Programmable Read Only Memory (PROM) EVAP Evaporative Emission Evaporative Emission Control (EVAP) FC Fan Control − FEEPROM Flash Electrically Erasable Programmable Read Only Memory − FEPROM Flash Erasable Programmable Read Only Memory − FF Flexible Fuel − FP Fuel Pump Fuel Pump GEN Generator Alternator GND Ground Ground (GND) − − − − − 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark IN−39 INTRODUCTION − TERMS HO2S Heated Oxygen Sensor Heated Oxygen Sensor (HO2S) IAC Idle Air Control Idle Speed Control (ISC) IAT Intake Air Temperature Intake or Inlet Air Temperature ICM Ignition Control Module IFI Indirect Fuel Injection IFS Inertia Fuel−Shutoff − ISC Idle Speed Control − KS Knock Sensor Knock Sensor MAF Mass Air Flow Air Flow Meter MAP Manifold Absolute Pressure Manifold Pressure Intake Vacuum MC Mixture Control Electric Bleed Air Control Valve (EBCV) Mixture Control Valve (MCV) Electric Air Control Valve (EACV) MDP Manifold Differential Pressure MFI Multiport Fuel Injection Electronic Fuel Injection (EFI) MIL Malfunction Indicator Lamp Check Engine Lamp MST Manifold Surface Temperature − MVZ Manifold Vacuum Zone − NVRAM Non−Volatile Random Access Memory − O2S Oxygen Sensor Oxygen Sensor, O2 Sensor (O2S) OBD On−Board Diagnostic On−Board Diagnostic System (OBD) OC Oxidation Catalytic Converter Oxidation Catalyst Convert (OC), CCo OP Open Loop Open Loop PAIR Pulsed Secondary Air Injection Air Suction (AS) PCM Powertrain Control Module − PNP Park/Neutral Position − PROM Programmable Read Only Memory − PSP Power Steering Pressure − PTOX Periodic Trap Oxidizer Diesel Particulate Filter (DPF) Diesel Particulate Trap (DPT) RAM Random Access Memory Random Access Memory (RAM) RM Relay Module ROM Read Only Memory Read Only Memory (ROM) RPM Engine Speed Engine Speed SC Supercharger Supercharger SCB Supercharger Bypass E−ABV SFI Sequential Multiport Fuel Injection Electronic Fuel Injection (EFI), Sequential Injection SPL Smoke Puff Limiter − SRI Service Reminder Indicator − SRT System Readiness Test − ST Scan Tool − TB Throttle Body Throttle Body TBI Throttle Body Fuel Injection Single Point Injection Central Fuel Injection (Ci) TC Turbocharger Turbocharger TCC Torque Converter Clutch 1996 LAND CRUISER (RM451U) − Indirect Injection (IDL) − − Torque Converter Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark IN−40 INTRODUCTION − TERMS TCM Transmission Control Module Transmission ECU, ECT ECU TP Throttle Position Throttle Position TR Transmission Range TVV Thermal Vacuum Valve Bimetallic Vacuum Switching Valve (BVSV) Thermostatic Vacuum Switching Valve (TVSV) TWC Three−Way Catalytic Converter Three−Way Catalytic (TWC) Manifold Converter CCRO TWC+OC Three−Way + Oxidation Catalytic Converter CCR + CCo VAF Volume Air Flow Air Flow Meter VR Voltage Regulator Voltage Regulator VSS Vehicle Speed Sensor Vehicle Speed Sensor WOT Wide Open Throttle Full Throttle WU−OC Warm Up Oxidation Catalytic Converter − WU−TWC Warm Up Three−Way Catalytic Converter − 3GR Third Gear − 4GR Fourth Gear − − 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark AC−1 AIR CONDITIONING − AIR CONDITIONING SYSTEM AIR CONDITIONING SYSTEM PRECAUTION 1. 2. AC2QA−01 DO NOT HANDLE REFRIGERANT IN AN ENCLOSED AREA OR NEAR AN OPEN FLAME ALWAYS WEAR EYE PROTECTION AC2810 3. AC2811 Wrong LO HI 6. Okay LO BE CAREFUL THAT LIQUID REFRIGERANT DOES NOT GET IN YOUR EYES OR ON YOUR SKIN If liquid refrigerant gets in your eyes or on your skin: (a) Wash the area with lots of cool water. CAUTION: Do not rub your eyes or skin. (b) Apply clean petroleum jelly to the skin. (c) Go immediately to a physician or hospital for professional treatment. 4. NEVER HEAT CONTAINER OR EXPOSE IT TO NAKED FLAME 5. BE CAREFUL NOT TO DROP CONTAINER AND NOT TO APPLY PHYSICAL SHOCKS TO IT HI N11084 DO NOT OPERATE COMPRESSOR WITHOUT ENOUGH REFRIGERANT IN REFRIGERANT SYSTEM If there is not enough refrigerant in the refrigerant system oil lubrication will be insufficient and compressor burnout may occur, so take care to avoid this. 7. DO NOT OPEN HIGH PRESSURE MANIFOLD VALVE WHILE COMPRESSOR IS OPERATING If the high pressure valve is opened, refrigerant flows in the reverse direction and could cause the charging cylinder to rupture, so open and close the only low pressure valve. 8. BE CAREFUL NOT TO OVERCHARGE SYSTEM WITH REFRIGERANT If refrigerant is overcharged, it causes problems such as insufficient cooling, poor fuel economy, engine overheating etc. 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 1328 Brought to you by BirfMark AC−2 AIR CONDITIONING − AIR CONDITIONING SYSTEM 9. SUPPLEMENTAL RESTRAINT SYSTEM (SRS) The LAND CRUISER is equipped with an SRS (Spplemental Restraint System)such as the driver airbag and passenger air bag. Failure to carry out service operations in the correct sequence could cause the SRS to unexpectedly deployed during servicing, possibly leading to a serious accident. Further, if a mistake is made in servicing the SRS, it is possible the SRS may fail to operate when required. Before servicing (including removal or installation of parts, inspection or replacement), be sure to read the following item carefully, then follow the correct procedure described in the repair manual. 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 1329 Brought to you by BirfMark AC−3 AIR CONDITIONING − AIR CONDITIONING SYSTEM AC2QC−03 PROBLEM SYMPTOMS TABLE Use the table below to help you find the cause of the problem.The numbers indicate the priority of the likely cause of the problem. Check each part in order. If necessary, replace these parts. Symptom Suspect Area HTR Fuse Heater main relay Blower motor Blower resistor Blower speed control switch Wire harness See page No blower operation 4. 5. 6. 7. 8. 9. No air temperature control 1. Engine coolant volume 2. A/C control assembly 3. Water valve − AC−69 AC−49 No compressor operation 1. Refrigerant volume 2. A.C Fuse 3. Magnetic clutch 4. Compressor 5. Pressure switch 6. Heater main relay 7. Blower speed control switch 8. A/C switch 9. A/C amplifier 10.Thermistor 11.Wire harness AC−5 − AC−33 AC−33 AC−61 AC−64 AC−69 AC−69 AC−74 AC−60 − Compressor operates intermitently 1. 2. 3. 4. 5. Refrigerant volume Pressure switch A/C amplifier Thermistor Wire harness AC−5 AC−61 AC−74 AC−60 − No cool air comes out 1. Refrigerant volume 2. Refrigerant pressure 3. Drive belt 4. Magnetic clutch 5. Compressor 6. Pressure switch 7. Thermistor 8. A/C switch 9. A/C amplifier 10.A/C control assembly 11.Wire harness AC−5 AC−5 AC−15 AC−33 AC−33 AC−61 AC−60 AC−69 AC−74 AC−69 − Cool air comes out only at high engine rpm 1. Refrigerant volume 2. Drive bel 3. Magnetic clutch 4. Compressor 5. Condenser 6. Receiver 7. Expansion valve 8. Evaporator 9. Thermistor 10.A/C amplifier 11.Wire harness AC−5 AC−15 AC−33 AC−33 AC−42 AC−39 AC−47 AC−45 AC−60 AC−74 − 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 − AC−64 AC−52 AC−57 AC−69 − Brought to you by BirfMark AC−4 AIR CONDITIONING − AIR CONDITIONING SYSTEM Insufficient cooling 1. Refrigerant volume 2. Drive belt 3. Magnetic clutch 4. Compressor 5. Condenser 6. Receiver 7. Expansion valve 8. Evaporator 9. Refrigerant line 10.Pressure switch 11.A/C amplifier 12.A/C control assembly AC−5 AC−15 AC−33 AC−33 AC−42 AC−39 AC−47 AC−45 AC−20 AC−61 AC−74 AC−69 No engine idle up when A/C switch ON 1. A/C amplifier 2. ECM 3. Wire harness AC−74 − − No warm air comes out 1. 2. 3. 4. Engine coolant volume A/C control assembly Water valve Heater radiator − AC−69 AC−49 AC−46 A/C indicator does not light up when mode lever at DEF. position 1. Defroster mode switch 2. A/C switch 3. Wire harness AC−69 AC−69 − Rear heater: Symptom Suspect Area See page No blower operation 1. 2. 3. 4. 5. RR HTR Fuse Rear heater relay Rear heater switch Rear blower motor Rear blower resistor − AC−65 AC−77 AC−55 AC−58 No warm air come out 1. Engine coolant volume 2. Rear heater radiator − AC−46 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark AC−5 AIR CONDITIONING N14063 Symptom 1 Bubbles present in sight glass 2 No bubbles present in sight glass 3 No temperature difference between compressor inlet and outlet 4 5 6 AIR CONDITIONING SYSTEM AC2QD−01 ON−VEHICLE INSPECTION Sight Glass Item − 1. INSPECT REFRIGERANT VOLUME Observe the sight glass on the liquid tube. Test conditions: S Running engine at 1,500 rpm S Blower speed control switch set at ”HI” S A/C switch ON S Temperature control set at ”MAX. COOL” S Fully open doors Amount of refrigerant Remedy Insufficient* 1. Check for gas leakage with gas leak tester and repair if necessary 2. Add refrigerant until bubbles disappear None, sufficient or too much Refer to items 3 and 4 Empty or nearly empty 1. Check for gas leakage with gas leak tester and repair if necessary 2. Add refrigerant until bubbles disappear Temperature between compressor inlet and outlet is noticeably different Correct or too much Refer to items 5 and 6 Immediately after air conditioning is turned off, refrigerant in sight glass stays clear Too much 1. Discharge refrigerant 2. Evacuate air and charge proper amount of purified refrigerant When air conditioning is turned off, refrigerant foams and then stays clear Correct − *: Bubbles in the sight glass with ambient temperatures higher than usual can be considered normal if cooling is sufficient. 2. INSPECT REFRIGERAT PRESSURE WITH MANIFOLD GAUGE SET This is a method in which the trouble is located by using a manifold gauge set. Read the manifold gauge pressure when the these conditions are established: Test conditions: S Temperature at the air inlet with the switch set at RECIRC is 30 − 35°C (86 − 95°F) S Engine running at 1,500 rpm S Blower speed control switch set at high S Temperature control set at max. cool HINT: It should be noted that the gauge indications may vary slightly due to ambient temperature conditions. (1) Normally functioning refrigeration system. Gauge reading: Low pressure side: 0.15 − 0.25 MPa (1.5 − 2.5 kgf/cm2) High pressure side: 1.37 − 1.57 MPa (14 − 15 kgf/cm2) I01386 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark AC−6 AIR CONDITIONING (2) − AIR CONDITIONING SYSTEM Moisture present in refrigeration system. Condition : Periodically cools and then fails to cool I01387 Symptom seen in refrigeration system Probable cause During operation, pressure on low pressure side sometimes become a vacuum and sometime normal Moisture entered in refrigeration system freezes at expansion valve orifice and temporarily stops cycle, but normal state is restored after a time when the ice melts Diagnosis (3) S Drier in oversaturated state S Moisture in refrigeration system freezes at expansion valve orifice and blocks circulation of refrigerant Remedy (1) Replace condenser (2) Remove moisture in cycle through repeatedly evacuating air (3) Charge proper amount of new refrigerant Insufficient cooling Condition: Insufficient cooling I01388 Symptom seen in refrigeration system S Pressure low on both low and high pressure sides S Bubbles seen in sight glass continuously S Insufficient cooling performance Probable cause Gas leakage at some place in refrigeration system Diagnosis S Insufficient refrigerant in system S Refrigerant leaking 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Remedy (1) Check for gas leakage with gas leak detector and repair if necessary (2) Charge proper amount of refrigerant (3) If indicated pressure value is near 0 when connected to gauge, create the vacuum after inspecting and repairing the location of the leak Brought to you by BirfMark AC−7 AIR CONDITIONING − (4) AIR CONDITIONING SYSTEM Poor circulation of refrigerant Condition: Insufficient cooling I01389 Symptom seen in refrigeration system Probable cause S Pressure low in both low and high pressure sides S Frost on tube from condenser to unit Refrigerant flow obstructed by dirt in condenser Diagnosis (5) condenser clogged Remedy Replace condenser Refrigerant does not circulate Condition: Does not cool (Cools from time to time in some cases) I01449 Symptom seen in refrigeration system S Vacuum indicated on low pressure side, very low pressure indicated on high pressure side S Frost or dew seen on piping before and after condenser/ drier or expansion valve Probable cause Diagnosis S Refrigerant flow obstructed by moisture or dirt in refrigeration system Refrigerant does not circulate S Refrigerant flow obstructed by gas leakage from expansion valve 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Remedy (1) Check expansion valve (2) Clean out dirt in expansion valve by blowing with air (3) Replace condenser (4) Evacuate air and charge new refrigerant to proper amount (5) For gas leakage from expansion valve, replace expansion valve Brought to you by BirfMark AC−8 AIR CONDITIONING (6) − AIR CONDITIONING SYSTEM Refrigerant overcharged or insufficient cooling of condenser Condition: Insufficient cooling I01390 Symptom seen in refrigeration system S Pressure too high on both low and high pressure sides S No air bubbles seen through the sight glass even when the engine rpm is lowered Probable cause S Unable to develop sufficient performance due to excessive refrigeration system S Insufficient cooling of condenser (7) Diagnosis Remedy S Excessive refrigerant in cycle → refrigerant over charged S Condenser cooling → condenser fins clogged or cooling fan faulty (1) Clean condenser (2) Check cooling fan with fluid coupling operation (3) If (1) and (2) are in normal state, check amount of refrigerant Charge proper amount of refrigerant Air present in refrigeration system Condition: Insufficient cooling NOTE : These gauge indications are shown when the refrigeration system has been opened and the refrigerant charged without vacuum purging. I01392 Symptom seen in refrigeration system S Pressure too high on both low and high pressure sides S The low pressure piping hot to touch S Bubbles seen in sight glass Probable cause Air entered in refrigeration system Diagnosis S Air present in refrigeration system S Insufficient vacuum purging 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Remedy (1) Check compressor oil to see if it is dirty or insufficient (2) Evacuate air and charge new refrigerant Brought to you by BirfMark AC−9 AIR CONDITIONING − (8) AIR CONDITIONING SYSTEM Expansion valve improperly Condition: Insufficient cooling I01450 Symptom seen in refrigeration system S Pressure too high on both low and high pressure sides S Frost or large amount of dew on piping on low pressure side Probable cause Diagnosis S Excessive refrigerant in low pressure piping S Expansion valve opened too wide Trouble in expansion valve (9) Remedy Check expansion valve Replace if defective Defective compression compressor Condition : Does not cool I01393 Symptom seen in refrigeration system S Pressure too high on low and high pressure sides S Pressure too low on high pressure side Probable cause Internal leak in compressor Diagnosis S Compression defective S Valve leaking or broken sliding parts 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Remedy Repair or replace compressor Brought to you by BirfMark AC−10 AIR CONDITIONING 3. (a) (b) − AIR CONDITIONING SYSTEM INSPECT IDLE−UP SPEED Warm up engine Inspect idle−up speed when the these conditions are established: S Blower switch HI S Electrical load OFF S A/C switch ON S Put gear shift in neutral Magnetic clutch condition Idle speed Magnetic clutch not engaged 650 ± 50 rpm Magnetic clutch engaged 800 ± 50 rpm If idle speed is not as specified, check the IAC valve and air intake system. 4. INSPECT FOR LEAKAGE OF REFRIGERANT (a) Perform in these conditions: S Stop engine. S Secure good ventilation (If not, the gas leak detector may react to volatile gases which are not refrigerant, such as evaporated gasoline and exhaust gas.) S Repeat the test 2 or 3 times. S Make sure that there is some refrigerant remaining in the refrigeration system. When compressor is OFF: approximately 392 − 588 KPa (4 − 6 kgf/cm2, 57 − 35 psi) (b) Bring the gas leak detector close to the drain hose before performing the test. HINT: S After the blower motor is stopped, leave the cooling unit for more than 15 minutes. S Expose the gas leak detector sensor the under the drain hose. S When bring the gas leak detector close to the drain hose, make sure that the gas leak detector does not react to the volatile gases. If such reaction is unavoidable, the vehicle must be lifted up. (c) If gas leak is not detected on the drain hose, remove the power transistor from the cooling unit. Then insert the gas leak detector sensor into the unit and perform the test. (d) Disconnect the connector and leave the pressure switch for approximately 20 minutes. Then bring the gas leak detector close to the pressure switch and perform the test. (e) Bring the gas leak detector close to the refrigerant lines and perform the test. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark AC−11 AIR CONDITIONING − AIR CONDITIONING SYSTEM EVACUATING 1. Quick Disconnect Adapter Charging Hose 2. 3. (a) (b) Service Valve N13795 AC2QE−01 CONNECT QUICK DISCONNECT ADAPTERS TO CHARGING HOSES REMOVE CAPS FROM SERVICE VALVES ON REFRIGERANT LINES INSTALL MANIFOLD GAUGE SET Close both hand valves of manifold gauge set. Connect the quick disconnect adapters to the service valves. 4. (a) EVACUATE AIR FROM REFRIGERATION SYSTEM Connect the vacuum pump adapter to the vacuum pump. (b) Connect the center hose of the manifold gauge set to the vacuum pump adapter. Open both the high and low hand valves and run the vacuum pump. After 10 minutes or more, check that the low pressure gauge indicates 750 mmHg (30 in.Hg) or more. Vacuum Pump Vacuum Pump Adapter N13794 Manifold Gauge Set (c) (d) HINT: If the reading is not 750 mmHg (30 in.Hg) or more, close both hand valves of manifold gauge set and stop the vacuum pump. Check the system for leaks and repair as necessary. (e) Close both the high and low hand valves and stop the vacuum pump. (f) Leave the system in this condition for 5 minutes or more and check that there is no gauge indicator. Low Pressure Service Valve High Pressure Service Valve Vacuum Pump Adapter N13791 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark AC−12 AIR CONDITIONING − AIR CONDITIONING SYSTEM CHARGING AC2QF−01 1. INSTALL CHARGING CYLINDER HINT: When handling the charging cylinder, always follow the direction given in the instruction manual. (a) Charge the proper amount of refrigerant in charging cylinder. (b) Connect the center hose to the charging cylinder. CAUTION: Do not open both high and low hand valves of manifold gauge set. (c) Open the valve of charging cylinder. (d) Press the valve core on the side of manifold gauge and expel the air inside of the center hose. Low Pressure Service Valve High Pressure Service Valve N13790 2. (a) INSPECT REFRIGERATION SYSTEM FOR LEAKS Open the high pressure hand valve and charge refrigerant. (b) When the low pressure gauge indicates 98 kPa (1 kgf/cm2, 14 psi), close the high pressure hand valve. (c) Using leak detector, check the system for leakage. (d) If leak is found, repair the faulty component or connection. Add evacuate air from refrigeration system (Refer to 4). CAUTION: Use the refrigerant recovery/ recycling machine to recover the refrigerant whenever replacing parts. Gas Leak Detector N13792 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark AT-1 AUTOMATIC TRANSMISSION - AUTOMATIC TRANSMISSION SYSTEM AUTOMATIC TRANSMISSION SYSTEM AT0SY-01 PRECAUTION If the vehicle is equipped with a mobile communication system, refer to the precautions in the IN section. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark AC−13 AIR CONDITIONING − AIR CONDITIONING SYSTEM 3. CHARGE REFRIGERANT INTO REFRIGERANT SYSTEM If there is no leak after refrigerant leak check charge, the proper amount of refrigerant into refrigeration system. CAUTION: Never run the engine when charging the system through the high pressure side.Do not open the low pressure hand valve when the system is being charged with liquid refrigerant. (a) Open the high pressure hand valve fully. (b) Charge specified amount of refrigerant, then close the high pressure hand valve. HINT: A fully charged system is indicated by the sight glass being free of any bubbles. 4. REMOVE MANIFOLD GAUGE SET (a) Close both hand valves of manifold gauge set. (b) Disconnect the quick disconnect adapters from the service valves. 5. INSTALL CAPS TO SERVICE VALVES ON REFRIGERANT LINES 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark AC−14 AIR CONDITIONING − AIR CONDITIONING SYSTEM AC2QB−01 POSITIONING Z04523 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark AC−15 AIR CONDITIONING − DRIVE BELT DRIVE BELT ON−VEHICLE INSPECTION AC2QG−01 1. INSPECT DRIVE BELT’S INSTALLATION CONDITION Check that drive belt fits properly in the ribbed groves. Correct Wrong CH0086 DENSO Borroughs N01881 2. INSPECT DRIVE BELT TENSION Using a belt tension gauge, check the drive belt tension. Belt tension gauge: DENSO BTG−20 (95506−00020) or Borroughs No. BT−33−73F Drive belt tension: New belt 100−150 lbf Used belt 60−100 lbf HINT: S ”New belt” refers to a belt which has been used less than 5 minutes on a running engine. S ”Used belt” refers to a belt which has been on a running engine for 5 minutes or more. S After installing the drive belt, check that it fits properly in the ribbed grooves. 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 1342 Brought to you by BirfMark AC−16 AIR CONDITIONING − DRIVE BELT REMOVAL 1. LOOSEN IDLE PULLEY LOCK NUT Torque: 39 N·m (400 kgf·cm, 29 ft·lbf) 2. REMOVE COMPRESSOR DRIVE BELT Loosen the adjusting bolt and remove the drive belt. N16451 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 AC2QH−01 Brought to you by BirfMark AC−17 AIR CONDITIONING − DRIVE BELT AC2QI−01 INSTALLATION Installation is in the reverse order of removal (See page AC−16). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark AC−18 AIR CONDITIONING − MANIFOLD GAUGE SET MANIFOLD GAUGE SET SET ON Low Pressure Charging Hose AC2QJ−01 1. CONNECT CHARGING HOSES TO MANIFOLD GAUGE SET Tighten the nuts by hand. CAUTION: Do not connect the wrong hoses. 2. CONNECT QUICK DISCONNECT ADAPTERS TO CHARGING HOSES Tighten the nuts by hand. 3. CLOSE BOTH HAND VALVES OF MANIFOLD GAUGE SET 4. REMOVE CAPS FROM SERVICE VALVES ON REFRIGERANT LINE High Pressure Charging Hose N14326 5. CONNECT QUICK DISCONNECT ADAPTERS TO SERVICE VALVES HINT: Push the quick disconnect adapter onto the service valve, then slide the sleeve of the quick disconnect adapter downward to lock it. Sleeve N04392 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 1345 Brought to you by BirfMark AC−19 AIR CONDITIONING − MANIFOLD GAUGE SET SET OFF 1. 2. t QJL = N06553 AC2QK−01 CLOSE BOTH HAND VALVES OF MANIFOLD GAUGE SET DISCONNECT QUICK DISCONNECT ADAPTERS FROM SERVICE VALVES ON REFRIGERANT LINE HINT: Slide the sleeve of the quick disconnect adapter upward to unlock the adapter and remove it from the service valve. 3. INSTALL CAPS TO SERVICE VALVES ON REFRIGERANT LINE 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark AC−20 AIR CONDITIONING − REFRIGERANT LINE REFRIGERANT LINE AC2QM−01 ON−VEHICLE INSPECTION 1. INSPECTION HOSE AND TUBE CONNECTIONS FOR LOOSENESS 2. INSPECT HOSES AND TUBES FOR LEAKAGE Using a gas leak detector, check for leakage of refrigerant. 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 1347 Brought to you by BirfMark AC−21 − AIR CONDITIONING REFRIGERANT LINE AC2QL−01 LOCATION 14 (140, 10) Liquid Tube 10 (100, 7) Pressure Switch 10 (100, 7) Suction Tube 10 (100, 7) 10 (100, 7) Suction Hose Receiver Discharge Hose 5.4 (55, 48 in.·lbf) Condenser 10 (100, 7) N·m (kgf·cm, ft·lbf) : Specified torque z Non−reusable part N14066 Z17947 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark AC−22 AIR CONDITIONING − REFRIGERANT LINE AC2QN−01 REPLACEMENT 1. DISCHARGE REFRIGERANT IN REFRIGERATION SYSTEM 2. REPLACE FAULTY TUBE OR HOSE NOTICE: Cap the open fittings immediately to keep moisture or dirt out of the system. 3. TORQUE CONNECTIONS TO SPECIFIED TORQUE NOTICE: Connections should not be torqued tighter than the specified torque. Part tightened N·m kgf·cm ft·lbf Compressor x Discharge hose 10 100 7 Compressor x Suction hose 10 100 7 Condenser x Discharge hose 10 100 7 Condenser x Liquid tube 10 100 7 Reciever x Liquid tube 5.4 55 48 in.·lbf Pressure switch x Liquid tube 10 100 7 Cooling unit x Liquid tube 10 100 7 Expansion valve x Evaporator 5.4 55 48 in.·lbf Cooling unit x Suction tube 10 100 7 Liquid tube (Piping joint) 14 140 10 Suction line (Block joint) 10 100 7 4. EVACUATE AIR IN REFRIGERATION SYSTEM AND CHARGE WITH REFRIGERANT Specified amount: 850 ± 50 g (29.98 ± 1.76 oz.) 5. INSPECT FOR LEAKAGE OF REFRIGERANT Using a gas leak detector, check for leakage of refrigerant. If there is leakage, check the tightening torque at the joints. 6. INSPECT AIR CONDITIONING OPERATION 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark AC−23 AIR CONDITIONING − COOLING UNIT COOLING UNIT AC3JL−01 COMPONENTS v ~ + Packing .?~-----Upper "JI'b,.;:y• Engine Coolant Temp. Cut Relay Unit Case c-----+ Packing Expansion Valve NC Amphfier - - - - - - ' > . . . , . J ) ~Gromet o«'-----Drain Hose Thermistor Lower Unit Case----" + Non-reusable part ~ ~ ~paCking . A~,,~ V~. ~':'-'-"~--Blower Resistor '~ N14361 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 1350 Brought to you by BirfMark AC−24 AIR CONDITIONING − COOLING UNIT REMOVAL 1. N06172 AC2QO−03 DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM HINT: At the time of installation, refer to the following procedure. S Evacuate air from refrigeration system. S Charge system with refrigerant and inspect for leakage of refrigerant. Specified amount: 850 ± 50 g (29.98 ± 1.76 oz.) 2. DISCONNECT SUCTION TUBE AND LIQUID TUBE FROM COOLING UNIT FITTING Remove the 2 bolts and both tubes. Torque: 10 N·m (100 kgf·cm, 7 ft·lbf) NOTICE: Cap the open fittings immediately to keep moisture or dirt out of the system. HINT: At the time of indtallation, lubricate 2 new O−rings with compressor oil and install the tubes. 3. (a) (b) 4. (a) (b) REMOVE THESE PARTS: Glove compratment door (See page BO−76) Glove compratment door reinforcement (See page BO−76) REMOVE COOLING UNIT Disconnect the connectors. Remove the 4 screws, 2 nuts and cooling unit. N14293 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark AC−25 AIR CONDITIONING − COOLING UNIT DISASSEMBLY AC2QP−01 1. REMOVE A/C AMPLIFIER 2. REMOVE RELAY 3. REMOVE WIRE HARNESS 4. REMOVE BLOWER RESISTOR Remove the 2 screws and blower resistor. 5. SEPARATE UPPER AND LOWER UNIT CASES (a) Using a knife, cut off the each packing. (b) Remove 3 clips and 4 screws. (c) Separate the upper and lower unit cases. 6. REMOVE EVAPORATOR FROM LOWER UNIT CASE HINT: If the evaporator was replaced, add compressor oil to the compressor. Add 40 cc (1.4 fl.oz.) Compressor oil: ND−OIL 8 or equivalent 7. REMOVE THERMISTOR Pull out the thermistor from the evaporator. 8. REMOVE EXPANSION VALVE Using a hexagon wrench, remove the 2 bolts and separate the expansion valve and evaporator. Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf) HINT: At the time of reassembly, lubricate 4 new O−rings with compressor oil and install the tubes. Hexagonal Wrench Expansion Valve N06174 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark AC−26 AIR CONDITIONING − COOLING UNIT AC2QQ−01 REASSEMBLY Reassembly is in the reverse order of disassembly (See page AC−25). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark AC−27 AIR CONDITIONING − COOLING UNIT AC2QR−01 INSTALLATION Installation is in the reverse order of removal (See page AC−24). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark AC−28 AIR CONDITIONING − HEATER UNIT HEATER UNIT AC2QS−01 REMOVAL 1. REMOVE COOLING UNIT (See page AC−24) 2. DRAIN ENGINE COOLANT FROM RADIATOR HINT: It is not necessary to drain out all the coolant. Hose ”A” 3. Hose ”B” (a) (b) DISCONNECT WATER HOSES FROM HEATER RADIATOR PIPES Grip the claws of the hose clip with pliers and slide the clip along the hose to a place where it does not clamp the hose to the pipe. Disconnect the water hoses. Z17942 Hose Clip ( ...~ I I I I I I I Paint Mark Heater Radiator Pope --------- HINT: S S I I I I I I I 4. 5. v- Water Hose Hose ”A” Hose ”B” 6. Push the water hose onto the heater radiator pipe as far as the ridge on the pipe. Install the hose clip in a position, as shown in the illustration. REMOVE PIPE GROMMETS REMOVE INSTRUMENT PANEL SAFETY PAD (See page BO−76) REMOVE INSTRUMENT PANEL REINFORCEMENT (See page BO−76) Upper FR RH RH 45° Marking 45 ± 10° N02485 N18179 N18181 10° FR Z17943 7. (a) REMOVE HEATER UNIT Remove the 3 screws and defroster nozzle. N06494 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 1355 Brought to you by BirfMark AC−29 AIR CONDITIONING (b) − HEATER UNIT Remove the 2 nuts and a screw, then remove heater unit. N06495 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 1356 Brought to you by BirfMark AC−30 AIR CONDITIONING − HEATER UNIT AC2QV−01 INSTALLATION Installation is in the reverse order of removal (See page AC−28). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark AC−31 AIR CONDITIONING − BLOWER UNIT BLOWER UNIT AC2R1−03 REMOVAL 1. 2. 3. (a) (b) REMOVE INSTRUMENT PANEL AND REINFORCEMENT (See page BO−76) REMOVE COOLING UNIT (See page AC−24) REMOVE BLOWER UNIT Disconnect the connectors. Remove the bolt and 2 nuts, then remove the blower unit. 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 1358 Brought to you by BirfMark AC−32 AIR CONDITIONING − BLOWER UNIT AC2R4−01 INSTALLATION Installation is in the reverse order of removal (See page AC−31). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark AC−33 AIR CONDITIONING − COMPRESSOR AND MAGNETIC CLUTCH COMPRESSOR AND MAGNETIC CLUTCH ON−VEHICLE INSPECTION AC2R5−01 1. INSTALL MANIFOLD GAUGE SET (See page AC−18) 2. START ENGINE Run the engine at 1,500 rpm. 3. INSPECT COMPRESSOR FOR METALLIC SOUND Check if there is a metallic sound from the compressor when the A/C switch is on. If metallic sound is heard, replace the compressor assembly. 4. INSPECT REFRIGERANT PRESSURE (See page AC−5) 5. STOP ENGINE 6. INSPECT VISUALLY FOR LEAKAGE OF REFRIGERANT FROM SAFETY SEAL Using a gas leak detector, check for leakage of refrigerant. If there is any leakage, replace the compressor assembly. 7. REMOVE MANIFOLD GAUGE SET (See page AC−19) 8. MAKE THESE VISUAL CHECKS: (a) Leakage of grease from the clutch bearing. (b) Signs of oil on the pressure plate or rotor. Repair or replace, as necessary. 9. INSPECT MAGNETIC CLUTCH BEARING FOR NOISE (a) Start engine. (b) Check for abnormal noise from near the compressor when the A/C switch is OFF. If abnormal noise is being emitted, replace the magnetic clutch. 10. (a) (b) INSPECT MAGNETIC CLUTCH Disconnect the connector from the magnetic clutch. Connect the positive (+) lead from the battery to the terminal on the magnetic clutch connector and the negative (−) lead to the body ground. (c) Check that the magnetic clutch is energized. If operation is not as specified, replace the magnetic clutch. N06158 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 1360 Brought to you by BirfMark AC−34 AIR CONDITIONING − COMPRESSOR AND MAGNETIC CLUTCH AC2R6−01 COMPONENTS Suction Hose 10 (100, 7) Compressor Bracket O−Ring 10 (100, 7) Discharge Hose 37 (375, 27) O−Ring 25 (250, 18) Compressor N·m (kgf·cm, ft·lbf) : Specified torque z Non−reusable part Drive Belt 37 (375, 27) N16453 Z17948 Rotor Pressure Plate 13.2 (135, 9) Shim Startor Compressor N14067 Snap Ring 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Z17949 Brought to you by BirfMark AC−35 AIR CONDITIONING − COMPRESSOR AND MAGNETIC CLUTCH DISASSEMBLY AC2R7−04 1. RUN ENGINE AT IDLE SPEED WITH A/C SWITCH ON FOR 10 MINUTES 2. STOP ENGINE 3. DISCONNECT NEGATIVE (−) TERMINAL CABLE FROM BATTERY 4. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM 5. DISCONNECT DISCHARGE AND SUCTION HOSES Remove the 2 bolts and disconnect the both hoses. NOTICE: Cap the open fittings immediately to keep the moisture or dirt out of the system. 6. REMOVE ENGINE UNDER COVER 7. REMOVE DRIVE BELT (See page AC−16) 8. REMOVE COMPRESSOR (a) Disconnect the connector. (b) 9. 10. (a) Remove the 4 bolts and pull the compressor upward. REMOVE COMPRESSOR (See page AC−35) REMOVE PRESSURE PLATE Using SST and a socket wrench, remove the shaft bolt. Torque: 13.2 N·m (135 kgf·cm, 9 ft·lbf) SST 07112−76060 (b) Install a SST on the pressure plate. SST 07112−66040 (c) Using SST and a socket wrench, remove the pressure plate. SST 07112−76060 SST AC0943 SST AC0944 SST AC0945 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark AC−36 AIR CONDITIONING − COMPRESSOR AND MAGNETIC CLUTCH (d) Remove the shims from the pressure plate. 11. (a) REMOVE ROTOR Using SST, remove the snap ring. SST 07114−84020 Shim Pressure Plate AC0946 SST AC0947 NOTICE: The snap ring should be installed so that its beveled side faces up. Snap Ring p R−Shape Compressor N20013 (b) Using a plastic hammer, tap the rotor off the shaft. NOTICE: Be careful not to damage the pulley when tapping on the rotor. AC1743 12. (a) REMOVE STATOR Disconnect the stator lead wire from the compressor housing. AC1744 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark AC−37 AIR CONDITIONING (b) − COMPRESSOR AND MAGNETIC CLUTCH Using SST, remove the snap ring. SST 07114−84020 SST AC0950 NOTICE: The snap ring should be installed so that its beveled side faces up. R−Shape 6 Snap Ring Stator Compressor N20012 (c) Remove the stator. Stator AC0951 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark AC−38 AIR CONDITIONING − COMPRESSOR AND MAGNETIC CLUTCH REASSEMBLY AC2R8−01 1. (a) INSTALL COMPRESSOR Install the compressor with the 4 bolts. Torque: 25 N·m (250 kgf·cm, 18 ft·lbf) (b) Connect the connector. 2. CONNECT DISCHARGE AND SUCTION HOSES Torque: 10 N·m (100 kgf·cm, 7 ft·lbf) NOTICE: Hoses should be connected immediately after the caps have been removed. HINT: Lubricate 2 new O−rings with compressor oil and install the hoses. 3. INSTALL AND INSPECT DRIVE BELT (See page AC−17) 4. INSTALL ENGINE UNDER COVER 5. CONNECT NEGATIVE (−) TERMINAL CABLE TO BATTERY 6. EVACUATE AIR FROM REFRIGERATION SYSTEM 7. CHARGE SYSTEM WITH REFRIGERANT AND INSPECT FOR LEAKAGE OF REFRIGERANT Specified amount: 850 ± 50 g (29.98 ± 1.76 oz.) Using a gas leak detector, check for leakage of refrigerant. If there is leakage, check the tightening torque at the joints. N04963 8. INSPECT A/C OPERATION Reassembly is in the reverse order of disassembly (See page AC−35). 9. CHECK CLEARANCE OF MAGNETIC CLUTCH (a) Set the dial indicator to the pressure plate of the magnetic clutch. (b) Connect the magnetic clutch lead wire to the positive (+) terminal of the battery. (c) Check the clearance between the pressure plate and rotor when connecting the negative (−) terminal to the battery. Standard clearance: 0.5 ± 0.15 mm (0.020 ± 0.0059 in.) If the clearance is not within the standard clearance, adjust the clearance using shims to obtain the standard clearance. Shim Thickness: 0.1 mm (0.004 in.) 0.3 mm (0.012 in.) 0.5 mm (0.020 in.) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark AC−39 AIR CONDITIONING − RECEIVER RECEIVER AC2RB−01 ON−VEHICLE INSPECTION INSPECT FITTINGS FOR LEAKAGE Using a gas leak detector, check for leakage. If there is leakage, check the tightening toque at the joints. 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 1366 Brought to you by BirfMark AC−40 AIR CONDITIONING − RECEIVER REMOVAL 1. AC2RC−01 DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM HINT: At the time of installation, refer to the following procedure. S Evacuate air from refrigeration system. S Charge system with refrigerant and inspect for leakage of refrigerant. Specified amount: 850 ± 50 g (29.98 ± 1.76 oz.) 2. DISCONNECT 2 LIQUID TUBES FROM RECEIVER Remove the 2 bolts and both tubes. Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf) NOTICE: Cap the open fittings immediately to keep moisture or dirt out of the system. HINT: At the time of installation, lubricate 2 new O−rings with compressor oil and install the tubes. 3. REMOVE RECEIVER FROM RECEIVER HOLDER Remove the holder bolt and pull the receiver down ward. HINT: If receiver was replaced, add compressor oil to compressor. Add 10 cc (0.35 fl.oz.) Compressor oil: ND−OIL 8 or equivalent N13975 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark AC−41 AIR CONDITIONING − RECEIVER AC2RD−01 INSTALLATION Installation is in the reverse order of removal (See page AC−40). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark AC−42 AIR CONDITIONING − CONDENSER CONDENSER AC2RG−01 ON−VEHICLE INSPECTION 1. INSPECT CONDENSER FINS FOR BLOCKAGE OR DAMAGE If the fins are clogged, wash them with water and dry with compressed air. NOTICE: Be careful not to damage the fins. If the fins are bent, straighten them with a screwdriver or pliers. 2. INSPECT CONDENSER AND FITTINGS FOR LEAKAGE Repair as necessary. 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 1369 Brought to you by BirfMark AC−43 AIR CONDITIONING − CONDENSER REMOVAL 1. AC2RE−01 DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM HINT: At the time of installation, refer to the following procedure. S Evacuate air from refrigeration system. S Charge system with refrigerant and inspect for leakage of refrigerant. Specified amount: 850 ± 50 g (29.98 ± 1.76 oz.) 2. REMOVE THESE PARTS: (a) Hood lock brace (b) Center brace 3. DISCONNECT DISCHARGE HOSE AND LIQUID TUBE Torque: 10 N·m (100 kgf·cm, 7 ft·lbf) NOTICE: Cap the open fittings immediately to keep moisture or dirt out of the system. HINT: At the time of installation, lubricate 2 new O−rings with compressor oil to compressor. 4. REMOVE CONDENSER (a) Remove 2 condenser mounting bolts. (b) Pull out the condenser between the radiator and the body. HINT: If condenser was replaced, add compressor oil to compressor. Add 40 cc (1.4 fl.oz.) Compressor oil: ND−OIL 8 or equivalent r----- . =:J__--_______ ----=.:-----~-- Condenser AC2674 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark AC−44 AIR CONDITIONING − CONDENSER AC2RF−01 INSTALLATION Installation is in the reverse order of removal (See page AC−43). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark AC−45 AIR CONDITIONING − EVAPORATOR EVAPORATOR AC2RJ−03 INSPECTION 1. REMOVE EVAPORATOR (See page AC−26) 2. CHECK EVAPORATOR FINS FOR BLOCKAGE If the fins are clogged, clean them with compressed air. NOTICE: Never use water to clean the evaporator. 3. CHECK FITTINGS FOR CRACKS OR SCRATCHES Repair as necessary. 4. REINSTALL EVAPORATOR (See page AC−26) 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 1372 Brought to you by BirfMark AC−46 AIR CONDITIONING − HEATER RADIATOR HEATER RADIATOR AC3JM−01 INSPECTION 1. REMOVE HEATER UNIT (See page AC−28) 2. REMOVE HEATER RADIATOR (a) Remove the screws and plates. (b) Pull the heater radiator out. 3. INSPECT FINS FOR BLOCKAGE If the fins are clogged, clean them with compressed air. 4. INSTALL HEATER RADIATOR 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 1373 Brought to you by BirfMark AC−47 AIR CONDITIONING − EXPANSION VALVE EXPANSION VALVE AC2RR−01 ON−VEHICLE INSPECTION 1. CHECK QUANTITY OF GAS DURING REFRIGERATION CYCLE 2. INSTALL MANIFOLD GAUGE SET 3. RUN ENGINE (a) Run the engine at 1,500 rpm for at least 5 minutes. (b) Then check that the high pressure reading is 1.37 − 1.57 MPa (14 − 16 kgf/cm2, 199 − 228 psi). 4. CHECK EXPANSION VALVE If the expansion valve is faulty, the low pressure reading will drop to 0 kPa (0 kgf/cm2, 0 psi). HINT: When the low pressure drops to 0 kPa (0 kgf/cm2, 0 psi), feel the receiver’s IN and OUT sides for zero temperature difference. 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 1374 Brought to you by BirfMark AC−48 AIR CONDITIONING − WATER VALVE WATER VALVE AC2RU−01 REMOVAL 1. DRAIN ENGINE COOLANT FROM RADIATOR HINT: It is not necessary to drain out all the coolant. 2. DISCONNECT WATER VALVE CONTROL CABLE 3. Hose ”A” (a) (b) DISCONNECT WATER HOSES FROM HEATER RADIATOR PIPE AND WATER VALVE Grip the claws of the hose clip with pliers and slide the clip along the hose to a place where it does not clamp the hose to the pipe. Disconnect the water hoses. Hose ”B” Z17944 Hose Clip Heater Radiator Pipe Paint Water Hose Hose ”A” Hose ”B” Upper Fr HINT: ATt the time of installation, refer to the following procedure. S Push the water hose onto the heater radiator pipe as far as ridge on the pipe. S Install the hose clip in a position, as shown in the illustration. 4. REMOVE WIRE HARNESS PROTECTOR 5. REMOVE WATER VALVE Remove the 2 bolts and water valve. Upper RH 45° Marking N02485 N18180 N18181 Z19353 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 1375 Brought to you by BirfMark AC−49 AIR CONDITIONING − WATER VALVE ADJUSTMENT AC2RW−01 ADJUST WATER VALVE CONTROL CABLE (a) Set the vehicle in these conditions. S Ignition switch on. S Blower speed control switch on. S Temperature control switch to ”COOL” position. (b) Set the water valve to ”COOL” position, install the control cable and lock the clamp. N14296 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark AC−50 AIR CONDITIONING − WATER VALVE AC2RV−01 INSTALLATION Installation is in the reverse order of removal (See page AC−48). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark AC−51 AIR CONDITIONING − FRONT BLOWER MOTOR FRONT BLOWER MOTOR REMOVAL AC3JN−01 1. REMOVE RH SCUFF PLATE 2. (a) REMOVE BLOWER MOTOR Disconnect the link from the lower cover. (b) Remove the 2 screws, then remove the lower cover while pushing the locking protrsion, as shown. Disconnect the connector from the blower motor. Remove the 3 screws and blower motor. f'05499 (c) (d) f()j5oo 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 1378 Brought to you by BirfMark AC−52 AIR CONDITIONING − FRONT BLOWER MOTOR INSPECTION AC2RY−01 INSPECT BLOWER MOTOR OPERATION Connect the positive (+) lead from the battery to terminal 2 and the negative (−) lead to terminal 1, then check that the motor operation is smooth. If operation is not as specified, replace the blower motor. AC2227 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark AC−53 AIR CONDITIONING − FRONT BLOWER MOTOR AC2RZ−01 INSTALLATION Installation is in the reverse order of removal (See page AC−51). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark AC−54 AIR CONDITIONING − REAR BLOWER MOTOR REAR BLOWER MOTOR REMOVAL 1. 2. (a) AC2S0−02 (b) REMOVE FRONT RH SEAT REMOVE BLOWER MOTOR Disconnect the connectors from the blower motor and rear heater relay. Remove the bolt and rear heater relay. (c) Remove the 2 screws and side cover. (d) Remove the bolt and 7 screws, then remove the upper cover with the blower motor. Remove the 3 screws and the blower motor. N14323 N14324 (e) N06504 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 1381 Brought to you by BirfMark AC−55 AIR CONDITIONING − REAR BLOWER MOTOR INSPECTION INSPECT BLOWER MOTOR OPERATION Connect the positive (+) lead from the battery to terminal 1 and the negative (−) lead to terminal 2, then check that the motor operations smoothly. If operation is not as specified, replace the motor. 1 2 AC2S1−02 2 BE2611 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark AC−56 AIR CONDITIONING − REAR BLOWER MOTOR AC2S2−01 INSTALLATION Installation is in the reverse order of removal (See page AC−54). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark AC−57 AIR CONDITIONING − BLOWER RESISTOR BLOWER RESISTOR AC3JO−01 INSPECTION 1. REMOVE GLOVE COMPARTMENT DOOR (See page BO−76) 2. REMOVE BLOWER RESISTOR Disconnect the connector and remove the 2 screws and blower resistor. ru;S12 2 1 4 3 H-4-2 3. INSPECT BLOWER RESISTOR RESISTANCE Measure resistance between terminals 1 and 4. Standard resistance: 1.8 − 2.2 Ω If resistance is not as specified, replace the blower resistor. 4. REINSTALL BLOWER RESISTOR N09039 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 1384 Brought to you by BirfMark AC−58 AIR CONDITIONING − REAR BLOWER RESISTOR REAR BLOWER RESISTOR AC3JP−01 INSPECTION 1. 2. (a) (b) REMOVE FRONT SEAT RH REMOVE BLOWER RESISTOR Disconnect the connector. Remove the 2 screws and blower resistor. 3. INSPECT REAR BLOWER RESISTOR CONTINUITY N06513 Connector ”A” 1 3 2 H-3-2 H-2-2 Connector ”B” Condition Tester connection Specified condition Constant A1 − B1 A2 − A3 − B2 Continuity If continuity is not as specified, replace the blower resistor. 4. REINSTALL REAR BLOWER RESISTOR 1 2 Z09802 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 1385 Brought to you by BirfMark AC−59 AIR CONDITIONING − THERMISTOR THERMISTOR ON−VEHICLE INSPECTION AC2S9−01 1. N14295 REMOVE GLOVE COMPARTMENT PARTS (See page BO−76) 2. INSPECT THERMISTOR RESISTANCE Measure the resistance between terminals. Standard resistance: 1,500 Ω at 25 °C (77 °F) If resistance is not as specified, replace the sensor. 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 1386 Brought to you by BirfMark AC−60 AIR CONDITIONING − THERMISTOR INSPECTION Thermometer Ice 1. 2. (a) 10 cm (3.9 in.) (Ω) 5,000~ I 4,500 ~ 4,000 ~ 3,500 ~l!o. 3,000 2,500 2,000 1,500 1,000 500 0 5 10 0 32 41 50 REMOVE THERMISTOR INSPECT THERMISTOR RESISTANCE Place the thermistor in cold water, while varying temperature of the water, measure resistance at the connector and at the same time, measure temperature of the water with a thermometer. Ohmmeter I03338 Thermistor (b) Compare the 2 readings on the chart. If resistance is not as specified, replace the thermistor. 3. REINSTALL THERMISTOR ~ 15 59 20 68 AC2SA−01 25(°C) 77 (°F) Z04352 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark AC−61 AIR CONDITIONING − PRESSURE SWITCH PRESSURE SWITCH ON−VEHICLE INSPECTION 1. 2. 3. AC2SB−01 INSTALL MANIFOLD GAUGE SET DISCONNECT CONNECTOR FROM PRESSURE SWITCH RUN ENGINE AT APPROX. 1,500 RPM N16452 Low Pressure Side High Pressure Side ON (Continuity) ~ 11 L 3,140 kpa 196 kpa (2.0 kgf·cm2, 28 psi) (32.0 kgf·cm2, 455 psi) OFF (No Continuity) OFF (No Continuity) Z13470 4. (a) INSPECT PRESSURE SWITCH OPERATION Connect the positive (+) lead from the ohmmeter to terminal 2 and the negative (−) lead to terminal 1. (b) Check continuity between terminals when refrigerant pressure is changed, as shown in the illustration. If operation is not as specified, replace the pressure switch. 5. STOP ENGINE AND REMOVE MANIFOLD GAUGE SET 6. CONNECT CONNECTOR TO PRESSURE SWITCH 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 1388 Brought to you by BirfMark AC−62 AIR CONDITIONING − PRESSURE SWITCH REMOVAL 1. N14163 AC2SC−01 DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM HINT: Evacuate air from refrigeration system. Charge system with refrigerant and inspect for leakage of refrigerant. Specified amount: 850 ± 50 g (29.98 ± 1.76 oz.) 2. REMOVE PRESSURE SWITCH (a) Disconnect the connector. (b) Remove the pressure switch from the liquid tube. Torque: 10 N·m (100 kgf·cm, 7 ft·lbf) HINT: At the time of installation, lubricate a new O−ring with compressor oil and install the switch. HINT: Lock the switch mount on the tube with an open end wrench, being careful not to deform the tube, and remove the switch. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark AC−63 AIR CONDITIONING − PRESSURE SWITCH AC2SD−01 INSTALLATION Installation is in the reverse order of removal (See page AC−62). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark AC−64 AIR CONDITIONING 3 2 HEATER MAIN RELAY HEATER MAIN RELAY 1 2 3 5 5 − 1 INSPECT HEATER MAIN RELAY CONTINUITY 4 4 BE1850 BEl S44 AC2SE−03 INSPECTION Z19533 Condition Tester connection Specified condition Constant 1−3 2−4 Continuity Apply B+ between terminals 3 and 5. 4−5 Continuity If continuity is not as specified, replace the relay. 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 1391 Brought to you by BirfMark AC−65 AIR CONDITIONING − REAR HEATER RELAY REAR HEATER RELAY AC2SF−01 INSPECTION 3 6 3 6 2 5 INSPECT REAR HEATER RELAY CONTINUITY 2 1 4 4 H-8-2 BE1844 1 Z09804 Condition Tester connection Specified condition Constant 2−6 1−3 Continuity Apply B+ between terminals 2 and 6. 1−4 Continuity If continuity is not as specified, replace the relay. 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 1392 Brought to you by BirfMark AC−66 AIR CONDITIONING 2 4 1 3 BE1647 BE1841 − MAGNETIC CLUTCH RELAY MAGNETIC CLUTCH RELAY 2 4 4 INSPECTION 1 AC2SG−01 INSPECT MAGNETIC CLUTCH RELAY CONTINUITY 3 Z09507 Condition Tester connection Specified condition Constant 1−3 Continuity Apply B+ between terminals 1 and 3. 2−4 Continuity If continuity is not as specified, replace the relay. 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 1393 Brought to you by BirfMark AIR CONDITIONING − ENGINE COOLANT TEMPERATURE (ECT) CUT RELAY AC−67 ENGINE COOLANT TEMPERATURE (ECT) CUT RELAY AC2SH−01 INSPECTION INSPECT SWITCH CONTINUITY Check the continuity betweeen terminals of the switch, as shown in the chart below. If continuity is not as specified, replace the switch. N06549 OFF _t 108°C (226°F) 103°C (217°F) ON f V02084 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 1394 Brought to you by BirfMark AC−68 AIR CONDITIONING − AIR CONDITIONING CONTROL ASSEMBLY AIR CONDITIONING CONTROL ASSEMBLY REMOVAL AC2SL−01 1. N14164 REMOVE INSTRUMENT CLUSTER FINISH CENTER PANEL WITH A/C CONTROL ASSEMBLY 2. REMOVE A/C CONTROL ASSEMBLY Remove the 3 screws and A/C control assembly from center panel. 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 1395 Brought to you by BirfMark AC−69 AIR CONDITIONING − AIR CONDITIONING CONTROL ASSEMBLY AC2SM−01 INSPECTION Mode Control Switch Connector "A" ~~.~r-r"""" ~ ~~ ill'O'~ 5 • 20 19iJl II 17 16115 a 13111211 10 9 AIC Switch & ru 7 6 Control Switch 2 1 -~ ...... L..... 2=i=~~~:=i~;=j::;5-H--+__ Blower Speed U3 Connector "B" ,...,.....& 7 ~ ~ 6 5 1& 17iJl16 15 L...,..L-,_ 'is" '-"'r"""".~~ r"'- ~'o"~ ullJ • ru 3 2 I 12 IliJllO 9 \-L..,- Temperature Control Switch .-20-2-C N0657 1 .-18-2-B Z04530 1. INSPECT ILLUMINATION OPERATION Connect the positive (+) lead from the battery to terminal A−13 and the negative (−) lead to terminal A−3, then check that the illuminations light up. If illuminations do not light up, test the bulb. Connector ”A” AC2717 2. r !rfl 1 7 20 19 lI: 8 m 6~5 4 17 16115 1413 3 2 12 11 1~ (a) ~ (b) Connector "A" ~e @j (c) Air Inlet Control Switch: INSPECT INDICATOR LIGHT OPERATION Connect the positive (+) lead from the battery to terminal A−9 and the negative (−) lead to terminal A−8. With the air inlet control button pushed in, check that the FRESH or RECIRC indicator light lights up. Next, push in the button again, and check that the indicator light goes off and the other indicator light lights up. AC2718 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark AC−70 AIR CONDITIONING AIR CONDITIONING CONTROL ASSEMBLY (d) Then connect the positive (+) lead from the battery to terminal A−13 and check that the indicator dims. If operation is not as specified, replace the A/C control assembly. r ~ 71 [lJ';W 5 41 3 2 11 1\E~g 1~17 16 115 14[.3] 12 11 1rf1 − 6 connector "A" ( .-r.. ' 1~ Ie CBI AC2719 3. Connector ”A” (a) (b) Connector ”B” Mode Control Switch: INSPECT INDICATOR LIGHT OPERATION Connect the positive (+) lead from the battery to terminal A−9 and the negative (−) lead to terminal B−16. Push each of the mode buttons in and check that their indicator light lights up. AC2722 (c) Then connect the positive (+) lead from the battery to terminal A−13 and check that the indicator dims. If operation is not as specified, replace the A/C control assembly. Connector ”A” Connector ”B” AC2723 4. Connector ”A” (a) (b) Connector ”B” Blower Speed Control Switch: INSPECT INDICATOR LIGHT OPERATION Connect the positive (+) lead from the battery to terminal A−9 and the negative (−) lead to terminal B−16. Push each of the blower speed control buttons in and check that their indicator light lights up. AC2722 (c) Then connect the positive (+) lead from the battery to terminal A−13 and check that the indicator dims. If operation is not as specified, replace the A/C control assembly. Connector ”A” Connector ”B” AC2723 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark AC−71 AIR CONDITIONING 5. Connector "A" (a) (b) Connector "B" − AIR CONDITIONING CONTROL ASSEMBLY A/C or DEF Switch: INSPECT INDICATOR LIGHT OPERATION Connect the positive (+) lead from the battery to terminal A−9 and the negative (−) lead to terminal B−18. Push the A/C or DEF switch button in and check that the indicator light lights up. AC2726 (c) Then, connect the positive (+) lead from the battery to terminal A−13 and check that the indicator dims. If operation is not as specified, replace the A/C control assembly. Connector "A" AC2727 6. Connector"A" ...-t • 20 It 7 , l' 17 ~~II B1 ~ 3 "lIB ,,113 12 11 10 2 I INSPECT AIR INLET CONTROL SWITCH CONTINUITY Switch position Tester connection Specified condition FRESH A8 − A19 Continuity RECIRC A8 − A18 Continuity If continuity is not as specified, replace the A/C control assembly. e-20-2-C 219129 7. Connector ”A” In, • [20 It 71' fIl';;l1 oT~ 31 2 ..117 ,,1 10 14 113 12111 I 10 1\ II Connector ”B” 0-20-2-<: .-18-2-B Z09805 INSPECT MODE CONTROL SWITCH CONTINUITY Switch position Tester connection Specified condition FACE A14 − B16 Continuity BI−LEVEL A12 − B16 Continuity FOOT A7 − B16 Continuity FOOT−DEF B11 − B16 Continuity DEF B4 − B16 Continuity If continuity is not as specified, replace the A/C control assembly. 8. INSPECT BLOWER SPEED CONTROL SWITCH CONTINUITY Switch position Tester connection Specified condition OFF A10 − B16 Continuity LO A1 − B16 Continuity M1 B9 − B16 Continuity M2 B10 − B16 Continuity HI B13 − B16 Continuity 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark AC−72 AIR CONDITIONING − AIR CONDITIONING CONTROL ASSEMBLY If continuity is not as specified, replace the A/C control assembly. 9. INSPECT A/C OR DEF SWITCH CONTINUITY Check that there is continuity between terminals B−6 and B−17 intermittently each time the A/C or DEF switch button pressed. If continuity is not as specified, replace the A/C control assembly. Connector "B" (1 3 IU 2 In !Ie 7 61 ~18 17 16 15 1(1 13 12111 5 [ll'O'H 1 1JlIO e·18·2·B 'Jl N06436 10. Connector "B" e-18-2-B N06436 INSPECT TEMPERATURE CONTROL SWITCH RESISTANCE (a) Measure resistance between terminals B−1 and B−2. Standard resistance: Approx. 3.0 kΩ (b) Check that the resistance between terminals B−1 and B−3 increases from 0 to approx. 3.0 kΩ when the switch knob is turned from COOL to HOT. If operation is not as specified, replace the A/C control assembly. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark AC−73 AIR CONDITIONING − AIR CONDITIONING CONTROL ASSEMBLY AC2SN−01 INSTALLATION Installation is the revese order of removal (See page AC−68). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark AC−74 AIR CONDITIONING − AIR CONDITIONING AMPLIFIER AIR CONDITIONING AMPLIFIER ON−VEHICLE INSPECTION AC2SI−01 INSPECT AMPLIFIER CIRCUIT (a) Disconnect the amplifier and inspect the connector on the wire harness side, as shown in the chart below. Test conditions: S Ignition switch ON S A/C switch ON S Temperature control lever MAX COOL S Blower control switch HI Tester connection Condition Specifeid condition 6 − Ground Constant Continuity 8−9 Constant Continuity 9−6 Constant Approx. 1.5 kΩ at 25 °C (77 °F) 2 − Ground A/C switch ON Battery positive voltage 2 − Ground A/C switch OFF No voltage 5 − Ground Start engine Approx. 10 to 14 v 5 − Ground Stop engine No voltage If circuit is as specified, try replacing the amplifier with a new one. If the circuit is not as specified, inspect the circuits connected to other parts. (b) Connect the connector to A/C amplifier and inspect wire harness side connector from the back side, as shown in the chart below. Test conditions: S Ignition switch ON S A/C switch ON S Temperature control lever MAX COOL S Blower control switch HI Tester connection Condition Specified Condition 3 − Ground Refrigeration pressure 2.0 − 32 kgf/cm3 3 − Ground Refrigeration pressure less than 2.0 − 32 kgf/cm3 or more Battery positive voltage No voltage If circuit is not as specified, replace the amplifier. 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 1401 Brought to you by BirfMark AC−75 AIR CONDITIONING − AIR CONDITIONING AMPLIFIER REMOVAL 1. 2. (a) (b) REMOVE GLOVE COMPARTMENT DOOR (See page BO−76) REMOVE A/C AMPLIFIER Disconnect the connector from the amplifier. Remove the screw and the amplifier. N14294 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 AC2SJ−01 Brought to you by BirfMark AC−76 AIR CONDITIONING − AIR CONDITIONING AMPLIFIER AC2SK−01 INSTALLATION Installation is in the reverse order of removal See page AC−75). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark AC−77 AIR CONDITIONING − REAR HEATER SWITCH REAR HEATER SWITCH AC2SO−04 INSPECTION 1. Z04536 REMOVE INSTRUMENT CLUSTER FINISH CENTER PANEL WITH A/C CONTROL ASSEMBLY 2. REMOVE REAR HEATER SWITCH 3. INSPECT INDICATOR OPERATION (a) Connect the positive (+) lead from the battery to terminal 5 and the negative (−) lead to terminal 1. (b) Push each of the rear heater switch knob in and check that their indicators lights up. If operation is not as specified, replace the switch. 4. INSPECT SWITCH CONTINUITY Switch position Tester connection Specified condition HI 1−4 Continuity OFF − No Continuity LO 1−2 Continuity Illumination circuit 3−6 Continuity If continuity is not as specified, replace the switch. Z15447 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 1404 Brought to you by BirfMark AT−2 AUTOMATIC TRANSMISSION − AUTOMATIC TRANSMISSION SYSTEM AT0SZ−01 OPERATION O/D Direct Clutch (C0) 2nd Coast Brake (B1) Forward Clutch (C1) Direct Clutch (C2) O/D Brake (B0) 1st & Reverse Brake (B3) Rear Planetary Carrier Rear Planetary Ring Gear 2nd Brake (B2) O/D Planetary No.1 One−Way Output Shaft Ring Gear Clutch (F1) Front & Rear Planetary O/D Planetary O/D One−Way Front Planetary Sun Gear Carrier Clutch (F0) Ring Gear No.2 One−Way O/D Planetary Clutch (F2) Front Planetary Sun Gear Carrier Input Shaft O/D Input Shaft Operating Shift Lever Position Gear Position P Parking R Reverse N Neutral C0 C1 C2 B0 B1 B2 B3 F0 F1 F2 1st D 2nd 3rd O/D 1st 2 2nd *1 3rd L 1st *2 2nd *1 Down−shift only in the 2 position and 3rd gear−no up−shift. *2 Down−shift only in the L position and 2nd gear−no up−shift. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 V07130 Brought to you by BirfMark AT−3 AUTOMATIC TRANSMISSION − SPEEDOMETER DRIVEN GEAR SPEEDOMETER DRIVEN GEAR ON−VEHICLE REPAIR 1. (a) (b) AT0T0−01 DISCONNECT SPEEDOMETER CABLE AND REMOVE SPEEDOMETER DRIVEN GEAR Loosen the serrated collar with pliers. Do not lose the felt dust protector and washer. Disconnect the speedometer cable. Q07268 (c) (d) (e) Remove the bolt and locking plate. Pry out the speedometer driven gear assembly. Remove the O−ring from the speedometer driven gear assembly. Remove the clip and speedometer driven gear from the speedometer driven gear sleeve. Q07264 2. REMOVE SPEEDOMETER DRIVEN GEAR OIL SEAL Using SST, remove the oil seal. SST 09921−00010 SST Z15453 3. REINSTALL SPEEDOMETER DRIVEN GEAR OIL SEAL Using SST, install a new oil seal. SST 09201−10000 (09201−01080) Drive in depth: 20 mm (0.79 in.) SST Z15454 4. (a) (b) (c) (d) Q07268 (e) REINSTALL SPEEDOMETER DRIVEN GEAR AND CONNECT SPEEDOMETER CABLE Install the clip and speedometer driven gear to the speedometer driven gear sleeve. Install a new O−ring to the speedometer driven gear assembly. Install the speedometer driven gear. Install the locking plate with the bolt. Torque: 16 N·m (160 kgf·cm, 12 ft·lbf) Connect the speedometer cable. 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 787 Brought to you by BirfMark AT−4 AUTOMATIC TRANSMISSION (f) − SPEEDOMETER DRIVEN GEAR Tighten the serrated collar with pliers. 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 788 Brought to you by BirfMark AT−5 AUTOMATIC TRANSMISSION − VEHICLE SPEED SENSOR VEHICLE SPEED SENSOR ON−VEHICLE REPAIR 1. Q07265 2. (a) (b) 3. (a) (b) 4. AT0T1−01 DISCONNECT NO.2 VEHICLE SPEED SENSOR CONNECTOR REMOVE NO.2 VEHICLE SPEED SENSOR Remove the bolt and No.2 vehicle speed sensor. Remove the O−ring from the No.2 vehicle speed sensor. REINSTALL NO.2 VEHICLE SPEED SENSOR Coat a new O−ring with ATF and install it to the No.2 vehicle speed sensor. Install the No.2 vehicle speed sensor and torque the bolt. Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf) RECONNECT NO.2 VEHICLE SPEED SENSOR CONNECTOR 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 789 Brought to you by BirfMark AT−6 AUTOMATIC TRANSMISSION − PARK/NEUTRAL POSITION (PNP) SWITCH PARK/NEUTRAL POSITION (PNP) SWITCH AT0T3−02 ON−VEHICLE REPAIR 1. 2. DISCONNECT 2 OIL COOLER PIPES (See page AT−16) DISCONNECT PARK/NEUTRAL POSITION SWITCH CONNECTOR 3. (a) (b) 4. (a) (b) Q07388 REMOVE PARK/NEUTRAL POSITION SWITCH Pry off the lock washer and remove the nut. Remove the bolt and park/neutral position switch. REINSTALL PARK/NEUTRAL POSITION SWITCH Install the park/neutral position switch and bolt. Install a new lock plate and the nut. Torque: 6.9 N·m (70 kgf·cm, 61 in.·lbf) (c) Stake the nut with the lock plate. (d) Adjust the park/neutral position switch. (See page DI−131) 5. RECONNECT PARK/NEUTRAL POSITION SWITCH CONNECTOR 6. RECONNECT 2 OIL COOLER PIPES (See page AT−17) Adjust the shift lever position. (See page DI−131) 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 790 Brought to you by BirfMark AT−7 AUTOMATIC TRANSMISSION − VALVE BODY ASSEMBLY VALVE BODY ASSEMBLY ON−VEHICLE REPAIR AT0T4−01 1. Q07274 DRAIN ATF Torque: 20 N·m (205 kgf·cm, 15 ft·lbf) 2. REMOVE OIL PAN NOTICE: Some fluid will remain in the oil pan. (a) Remove the 19 bolts. Torque: 7.4 N·m (75 kgf·cm, 65 in.·lbf) (b) Install the blade of SST between the transmission case and oil pan, cut off applied sealer and then remove the oil pan. SST 09032−00100 NOTICE: When removing the oil pan, be careful not to damage the oil pan flange. SST AT3168 HINT: At the time of installation, after removing all the old FIPG on the contacting surface of the oil pan and transmission case, apply new FIPG to the oil pan.(See page AT−1) FIPG: Part No. 08826−00090, THREE BOND 1281 or equivalent Seal Breadth 2 − 3 mm AT1362 3. (a) (b) WHEN REPLACING 3 SHIFT SOLENOID VALVES Disconnect the connectors from the solenoid valves. Remove the 3 solenoid valve mounting bolts. Torque: 10 N·m (100 kgf·cm, 7 ft·lbf) Remove the 3 solenoid valves. (c) HINT: At the time of installation, replace the O−rings with new ones. 4. REMOVE OIL STRAINER Remove the 4 bolts, and the oil strainer and gaskets. Torque: 10 N·m (100 kgf·cm, 7 ft·lbf) NOTICE: Be careful as some fluid will come out with the oil strainer. Bolt length: Bolt A: 16 mm (0.63 in.) Bolt B: 20 mm (0.79 in.) Bolt C: 28 mm (1.10 in.) 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 791 Brought to you by BirfMark AT−8 AUTOMATIC TRANSMISSION − VALVE BODY ASSEMBLY HINT: At the time of installation, replace the gaskets with new ones. 5. REMOVE OIL PIPE Pry up both pipe ends with a large screwdriver and remove the pipe. NOTICE: At time of the installation, make sure that the oil pipe or the magnet do not interfere with the oil pan. A B A B B B B A 6. DISCONNECT CONNECTOR FROM EACH SOLENOID VALVE 7. (a) REMOVE VALVE BODY Remove the 17 bolts. Torque:10 N·m (100 kgf·cm, 7 ft·lbf) Bolt length: Bolt A: 23 mm (0.91 in.) Bolt B: 32 mm (1.26 in.) Z11798 (b) Disconnect the throttle cable from the cam. (c) Remove the valve body. NOTICE: Be careful not to drop the check ball body and spring. HINT: At the time of installation, install the body together the check ball body and spring and Align the groove of the manual valve to the pin of the lever. AT1369 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 792 Brought to you by BirfMark AT−9 AUTOMATIC TRANSMISSION − VALVE BODY ASSEMBLY 8. REINSTALL VALVE BODY ASSEMBLY To install, follow the removal procedure in reverse. HINT: After installation, fill ATF and check the fluid level. (See page DI−131) 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 793 Brought to you by BirfMark AT−10 AUTOMATIC TRANSMISSION − PARKING LOCK PAWL PARKING LOCK PAWL ON−VEHICLE REPAIR AT0T5−02 1. REMOVE VALVE BODY (See page AT−7) 2. REMOVE PARKING LOCK PAWL BRACKET 3. REMOVE SPRING FROM PARKING LOCK PAWL SHAFT AT1366 AT2000 AT2001 4. REMOVE PARKING LOCK PAWL AND SHAFT 5. REINSTALL PARKING LOCK PAWL AND SHAFT 6. REINSTALL SPRING 7. REINSTALL PARKING LOCK PAWL BRACKET HINT: S Push the lock rod fully forward. S Check that the parking lock pawl operates smoothly. Torque: 7.4 N·m (75 kgf·cm, 65 in.·lbf) 8. REINSTALL VALVE BODY (See page AT−7) 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 794 Brought to you by BirfMark AT−11 AUTOMATIC TRANSMISSION − THROTTLE CABLE THROTTLE CABLE AT0T6−01 ON−VEHICLE REPAIR 1. (a) (b) DISCONNECT THROTTLE CABLE Disconnect the cable from the throttle linkage. Disconnect the cable from the cable clamps in the engine compartment. (c) Remove the bolt and disconnect the cable clamp from the torque converter clutch housing. 2. REMOVE VALVE BODY (See page AT−7) 3. REMOVE THROTTLE CABLE Remove the retaining bolt and pull out the throttle cable. 4. REINSTALL THROTTLE CABLE (a) To install, follow the removal procedure in reverse. AT6684 200 mm (7.87 in.) 0.8 − 1.5 mm (0.031 − 0.059 in.) Q05731 HINT: If throttle cable is new, stake the stopper on the inner cable. (b) Bend the cable so there is a radius of about 200 mm (7.87 in.) (c) Pull the inner cable lightly until slight resistance is felt, and hold it there. (d) Stake the stopper, 0.8−1.5 mm (0.031−0.059 in.) from the end of outer cable. S After installation, fill ATF and check the fluid level (See page DI−131). S Adjust the throttle cable (See page DI−131). 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 795 Brought to you by BirfMark AT−12 − AUTOMATIC TRANSMISSION SHIFT LOCK SYSTEM SHIFT LOCK SYSTEM AT0YZ−01 LOCATION Key Interlock Solenoid Stop Light Switch Shift Lock Solenoid Shift Lock Control Switch Shift Lock Control ECU Ignition Switch CIG ACC IG FL AM1 STOP ECU − IG SLS+ Stop Light Switch STP Shift Lock Control Switch Battery ACC Shift Lock Solenoid FL ALT MAIN FL IG Shift Lock Control ECU SLS− Key Interlock Solenoid P1 Stop Light KLS P2 P E Z16651 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 796 Brought to you by BirfMark AT−13 AUTOMATIC TRANSMISSION A IG STP E B ACC SLS− − SHIFT LOCK SYSTEM INSPECTION C AT0T7−04 1. INSPECT SHIFT LOCK CONTROL ECU Using a voltmeter, measure the voltage at each terminal. HINT: Do not disconnect the ECU connector. SLS+ KLS Z16656 Ohmmeter 2. (a) (b) INSPECT SHIFT LOCK SOLENOID Disconnect the solenoid connector. Using an ohmmeter, measure the resistance between terminals. Standard resistance: 20 − 28 Ω If the resistance is not as specified, replace the solenoid. Q07316 (c) Apply the battery positive voltage between terminals. At this time, confirm that solenoid operate. If the operation is not as specified, replace the solenoid. Battery Q07315 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark AT−14 AUTOMATIC TRANSMISSION − SHIFT LOCK SYSTEM 3. (a) (b) INSPECT KEY INTERLOCK SOLENOID Disconnect the solenoid connector. Using an ohmmeter, measure the resistance between terminals 7 and 8. Standard resistance: 12 − 17 Ω If the resistance is not as specified, replace the solenoid. 4. INSPECT SHIFT LOCK CONTROL SWITCH Inspect that there is continuity between each terminal. P1 P2 P Q07314 Shift position Tester condition to terminal number Specified value P position (Release button is not pushed) P1 − P Continuity P position (Release button is pushed) P1 − P P2 − P Continuity R, N, D, 2, L position P2 − P Continuity If the continuity is not as specified, replace the switch. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark AT−15 AUTOMATIC TRANSMISSION − AIR COOLED OIL COOLER AIR COOLED OIL COOLER AT0T8−01 COMPONENTS Oil Cooler Radiator Grille Q07275 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 799 Brought to you by BirfMark AT−16 AUTOMATIC TRANSMISSION − AIR COOLED OIL COOLER REMOVAL 1. REMOVE RADIATOR GRILLE (a) Remove the 5 screws. (b) Using a screwdriver, disconnect the clip. HINT: Tape a screwdriver tip before use. (c) Remove the radiator grille. 2. (a) REMOVE OIL COOLER Loosen the 2 clips and disconnect the 2 hoses. (b) Remove the 8 bolts and oil cooler. Torque: 11 N·m (115 kgf·cm, 8 ft·lbf) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 AT0T9−01 Brought to you by BirfMark AT−17 AUTOMATIC TRANSMISSION − AIR COOLED OIL COOLER AT0TA−01 INSTALLATION Installation is in the reverse order of removal (See page AT−16). HINT: After installation, check fluid level (See page DI−131). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark AT−18 AUTOMATIC TRANSMISSION − AUTOMATIC TRANSMISSION UNIT AUTOMATIC TRANSMISSION UNIT AT0TB−01 COMPONENTS Hold Down Clamp Battery Battery Tray Starter Fan Shroud Level Gauge Front Propeller Shaft z Oil Filler Pipe z Gasket z O−Ring z Gasket z z Hole Plug Engine Under Cover Stabilizer Bar Crossmember with Transfer Under Cover z Non−reusable Part Q08463 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 802 Brought to you by BirfMark AT−19 AUTOMATIC TRANSMISSION − AUTOMATIC TRANSMISSION UNIT Transfer Shift Lever Boot Rear Propeller Shaft x6 Transmission Shif Lever Assembly Transfer Shift Lever Knob Transfer Shift Control Link Clip Transfer Shift Lever Cushion Front Console Box Rear Console Box Oil Cooler Pipe Engine Rear Mounting x6 Plug for Hydraulic Test Q08467 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 803 Brought to you by BirfMark AT−20 AUTOMATIC TRANSMISSION − AUTOMATIC TRANSMISSION UNIT REMOVAL AT0TC−01 1. 2. REMOVE BATTERY AND BATTERY TRAY REMOVE 2 BOLTS AND LOOSEN FAN SHROUD OF COOLING FAN TO AVOID DAMAGE TO FAN Torque: 4.9 N·m (50 kgf·cm, 43 in.·lbf) 3. (a) DISCONNECT THROTTLE CABLE Loosen the adjusting nut and disconnect the cable from the bracket. Disconnect the throttle cable from the linkage. (b) 4. REMOVE UPPER SIDE STARTER MOUNTING BOLT Torque: 39 N·m (400 kgf·cm, 29 ft·lbf) 5. REMOVE TRANSMISSION SELECT LEVER AND TRANSFER SHIFT LEVER Remove the clip, washer and wave washer, and disconnect the transfer shift lever link. (a) (b) Remove the nut and washer, and disconnect the transmission select lever link. Torque: 13 N·m (130 kgf·cm, 9 ft·lbf) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark AT−21 AUTOMATIC TRANSMISSION − AUTOMATIC TRANSMISSION UNIT (c) (d) Remove the transfer shift lever knob. Remove the 4 screws and console. (e) Remove the 4 screws and transfer shift lever boot. (f) Remove the 3 bolts and console box. (g) Disconnect the 3 connectors. (h) Remove the 6 screws and transmission shift lever assembly. Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark AT−22 AUTOMATIC TRANSMISSION (i) (j) 6. S S S S S S S S 7. 8. 9. (a) (b) − AUTOMATIC TRANSMISSION UNIT Remove the 4 bolts and transfer shift lever. Torque: 18 N·m (185 kgf·cm, 13 ft·lbf) Remove the 2 cushions. DISCONNECT THESE CONNECTORS: No.1 vehicle speed sensor No.2 vehicle speed sensor Park/neutral position switch Solenoid connector ATF temperature sensor Center differential lock indicator switch L4 position switch Neutral position switch DISCONNECT BLEEDER HOSE FROM TRANSFER REMOVE FRONT AND REAR PROPELLER SHAFT (See page PR−3) REMOVE OIL FILLER PIPE Remove the level gauge. Remove the upper side mounting bolt. (c) Remove the bolt and filler pipe. HINT: At the time of installation, replace the used O−ring with a new one. 10. LOOSEN 2 OIL COOLER PIPE UNION NUTS Torque: 34 N·m (350 kgf·cm, 25 ft·lbf) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark AT−23 AUTOMATIC TRANSMISSION 11. − AUTOMATIC TRANSMISSION UNIT REMOVE 4 STABILIZER BAR BRACKET MOUNTING BOLTS Torque: 18 N·m (185 kgf·cm, 13 ft·lbf) 12. REMOVE ENGINE UNDER COVER Remove the 4 bolts and engine under cover. Torque: 28 N·m (290 kgf·cm, 21 ft·lbf) 13. (a) (b) (c) REMOVE TORQUE CONVERTER CLUTCH MOUNTING BOLT Remove the converter hole plug. Turn the crankshaft to gain access to each bolt. Hold the crankshaft pulley nut with a wrench and remove the 6 bolts. Torque: 55 N·m (550 kgf·cm, 40 ft·lbf) HINT: At the time of installation, first install gray colored bolt and then 5 other bolts. 14. REMOVE FRONT EXHAUST PIPE ASSEMBLY (a) Remove the 2 nuts, bolts and gasket, and disconnect the front exhaust pipe assembly. Torque: 39 N·m (400 kgf·cm, 29 ft·lbf) HINT: At the time of inatallation, replace the used nuts and gasket with new nuts and gasket. (b) Loosen the clamp bolt and disconnect the clamp from the No.1 support bracket. Torque: 19 N·m (195 kgf·cm, 14 ft·lbf) (c) Remove the 2 bolts and No.1 support bracket. Torque: 24 N·m (240 kgf·cm, 17 ft·lbf) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark AT−24 AUTOMATIC TRANSMISSION (d) − AUTOMATIC TRANSMISSION UNIT Remove the 4 nuts and 2 gaskets, shift the front exhaust pipe assembly to the vehicle’s outside. Torque: 62 N·m (630 kgf·cm, 46 ft·lbf) HINT: At the time of installation, replace the used gaskets and nuts with new gaskets and nuts. 15. (a) (b) 16. (a) (b) REMOVE STARTER Remove the nut and disconnect the terminal and connector. Remove the lower side mounting bolt and starter. Torque: 39 N·m (400 kgf·cm, 29 ft·lbf) REMOVE CROSSMEMBER Support the transmission with a transmission jack. Remove the 8 bolts and 2 nuts, and then remove the crossmember. Torque: Bolt: 61 N·m (620 kgf·cm, 45 ft·lbf) Nut: 74 N·m (750 kgf·cm, 54 ft·lbf) Q07409 17. REMOVE TRANSMISSION (a) Lower the rear end of the transmission. NOTICE: Be careful not to damage the cooling fan, brake booster and brake line. (b) Separate the wire harness from the transmission and transfer. (c) Remove the oil cooler pipe mounting bolts from the torque converter clutch housing, and then disconnect the 2 oil cooler pipes from the elbows. (d) Remove the 10 bolts and transmission. Torque: 72 N·m (730 kgf·cm, 53 ft·lbf) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark AT−25 AUTOMATIC TRANSMISSION − AUTOMATIC TRANSMISSION UNIT INSTALLATION 1. AT0TD−01 CHECK TORQUE CONVERTER CLUTCH INSTALLATION Using calipers and a straight edge, measure from the installed surface of the transmission housing. Correct distance: More than 15.7 mm (0.618 in.) 2. INSTALL TRANSMISSION Installation is in the reverse order of removal (See page AT−20). HINT: S After installation, adjust the shift lever position and throttle cable (See page DI−131). S Fill and check fluid level (See page DI−131). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BE−1 BODY ELECTRICAL − BODY ELECTRICAL SYSTEM BODY ELECTRICAL SYSTEM BE1LS−01 PRECAUTION Take care to observe the following precautions when performing inspections or removal and replacement of body electrical related parts. 1. HEADLIGHT SYSTEM Halogen bulbs have pressurized gas inside and require special handling. They can burst if scratched or dropped. Hold a bulb only by its plastic or metal case. Don’t touch the glass part of a bulb with bare hands. 2. SRS (SUPPLEMENTAL RESTRAINT SYSTEM) The LAND CRUISER is equipped with an SRS (Supplemental Restraint System) such as the driver airbag and front passenger airbag. Failure to carry out service operation in the correct sequence could cause the SRS to unexpectedly deploy during servicing, possibly leading to a serious accident. Before servicing (including removal or installation of parts, inspection or replacement), be sure to read the precautionary notices in the RS section. 3. AUDIO SYSTEM If the negative (−) terminal cable is disconnected from the battery, the preset AM, FM 1 and FM 2 stations stored in memory are erased, so be sure to note the stations and reset them after the negative (−) terminal cable is reconnected to the battery. 4. MOBILE COMMUNICATION SYSTEM If the vehicle is equipped with a mobile communication system, refer to precautions in the IN section. 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 1139 Brought to you by BirfMark BE−2 BODY ELECTRICAL − BODY ELECTRICAL SYSTEM BE1LT−01 PROBLEM SYMPTOMS TABLE IGNITION SWITCH AND KEY UNLOCK WARNING SWITCH Symptom Suspect Area See page Ignition switch is not set to each position. 5. Ignition Switch BE−11 ”Key unlock warning system” does not operate. 1. 2. 3. 4. − BE−11 BE−21 − GAUGE Fuse (I/P F/B) Key Unlock Warning Switch Door Courtesy Switch Wire Harness HEADLIGHT AND TAILLIGHT SYSTEM Symptom Suspect Area See page Headlight does not light up. (Taillight is normal.) 1. 2. 3. 4. 5. 6. 7. Headlight Bulb MAIN FL HEAD (LH) Fuse (No.2 R/B) HEAD (RH) Fuse (No.2 R/B) Light Control Switch Headlight Dimmer Switch Wire Harness − − − − BE−14 BE−14 − Headlight does not light up. (Taillight does not light up.) 1. 2. 3. 4. Headlight Bulb Light Control Switch Headlight Dimmer Switch Wire Harness − BE−14 BE−14 − Only one light comes ON. 1. 2. 3. 4. Headlight Bulb HEAD (LH) Fuse (No.2 R/B) HEAD (RH) Fuse (No.2 R/B) Wire Harness ”Lo−Beam” does not light up. 1. 2. 3. 4. Headlight Bulb Headlight Control Relay (No.2 R/B) Headlight Dimmer Switch Wire Harness − − BE−14 − ”Hi−Beam” does not light up. 1. 2. 3. 4. Headlight Bulb Headlight Control Relay (No.2 R/B) Headlight Dimmer Switch Wire Harness − − BE−14 − ”Flash” does not light up. 1. 2. 3. 4. Headlight Bulb Headlight Control Relay (No.2 R/B) Headlight Dimmer Switch Wire Harness − − BE−14 − Taillight does not light up. (Headlight is normal.) 1. 2. 3. 4. 5. Taillight Bulb TAIL Fuse (I/P F/B) Light Control Switch Taillight Control Relay (No.2 R/B) Wire Harness − − BE−14 BE−14 − Taillight does not light up. (Headlight does not light up.) 1. 2. 3. 4. 5. Taillight Bulb MAIN FL TAIL Fuse (I/P F/B) Light Control Switch Wire Harness − − − BE−14 − Headlight and Taillight does not light. 1. Light Control Switch 2. Wire Harness BE−14 − 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 − − − − Brought to you by BirfMark BE−3 BODY ELECTRICAL Only one side taillight does not light. BODY ELECTRICAL SYSTEM 1. Taillight Bulb 2. Wire Harness 1. 2. 3. 4. 5. Taillight does not light. (Headlight is normal.) − − − Taillight Bulb TAIL Fuse (No.2 R/B) Taillight Control Relay (No.2 R/B) Light Control Switch Wire Harness − BE−14 BE−14 BE−14 − TURN SIGNAL AND HAZARD WARNING SYSTEM Symptom Suspect Area See page ”Hazard” and ”Turn” do not light up. 1. Hazard Warning Switch 2. Turn Signal Flasher (No.1 R/B) 3. Wire Harness BE−19 BE−19 − None of blinks for hazard. (Turn is normal.) 1. Bulb 2. Turn Signal Flasher (No.1 R/B) 3. Wire Harness − BE−19 − Hazard warning light does not light up. (Turn is normal.) 1. HAZ − HORN Fuse (No.2 R/B) 2. Wire Harness BE−19 − Hazard warning light does not light up in one direction. 1. Hazard Warning Switch 2. Wire Harness BE−19 − The flashing frequency is abnormal. 1. Bulb 2. Turn Signal Flasher (No.1 R/B) 3. Wire Harness − BE−19 − Turn signal does not light up in one direction. 1. Turn Signal Switch 2. Wire Harness BE−19 − Only one bulb does not light up for hazard turn. 1. Bulb 2. Wire Harness Turn signal does not light up. (Combination meter, wiper and washer do not operate.) 1. 2. 3. 4. Ignition Switch TURN Fuse (I/P F/B) Turn Signal Switch Wire Harness BE−11 BE−19 BE−19 − Turn signal does not light up. (Combination meter, wiper and washer are normal.) 1. TURN Fuse (I/P F/B) 2. Turn Signal Switch 3. Wire Harness BE−19 BE−19 − − − INTERIOR LIGHT SYSTEM Symptom Suspect Area Room light does not light up. 1. 2. 3. 4. 5. 6. DOME Fuse (No.2 R/B) Door Courtesy Switch Front Personal Light Room Light Assembly Bulb Wire Harness Room light remains always on. 1. Door Courtesy Switch 2. Wire Harness See page − BE−21 BE−21 BE−21 − − BE−21 − BACK−UP LIGHT SYSTEM Symptom Back−Up light does not light up. Suspect Area 1. 2. 3. 4. 5. GAUGE Fuse (I/P F/B) Ignition Switch Park/Neutral Position Switch (A/T) Bulb Wire Harness 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 See page − BE−11 − − − Brought to you by BirfMark BE−4 BODY ELECTRICAL − BODY ELECTRICAL SYSTEM Back−Up light remains on. 1. Park/Neutral Position Switch (A/T) 2. Wire Harness − − Only one light does not light up. 1. Bulb 2. Wire Harness − − STOP LIGHT SYSTEM Symptom Suspect Area Stop light does not light up. 1. 2. 3. 4. STOP Fuse (I/P F/B) Stop Light Switch Bulb Wire Harness Stop light remains always on. 1. Stop Light Switch 2. Wire Harness Only one light does not light up. 1. Wire Harness 2. Bulb See page − BE−25 − − BE−25 − − − WIPER AND WASHER SYSTEM Symptom Suspect Area See page Wipers do not operate or return to off position. 1. 2. 3. 4. 5. WIPER Fuse (I/P F/B) Wiper Switch Wiper Motor Wiper Relay Wire Harness BE−27 BE−27 BE−27 BE−27 − Wipers do not operate in MIST. 1. 2. 3. 4. Wiper Switch Wiper Motor Wiper Relay Wire Harness BE−27 BE−27 BE−27 − Wipers do not operate in INT. 1. 2. 3. 4. Wiper Switch Wiper Motor Wiper Relay Wire Harness BE−27 BE−27 BE−27 − Washer does not operate. 1. 2. 3. 4. Washer Hose or Nozzle Clogged Washer Switch Washer Motor Wire Harness − BE−27 BE−27 − METER, GAUGES AND ILLUMINATION: COMBINATION METER Symptom Suspect Area See page Tachometer, speedometer, engine coolant temperature gauge and fuel gauge do not operate. 1. GAUGE Fuse (I/P F/B) 2. Meter Circuit 3. Wire Harness − BE−32 − Speedometer does not operate. 1. 2. 3. 4. BE−34 − BE−32 − Tachometer does not operate. 1. Meter Circuit 2. Igniter 3. Wire Harness BE−32 − − Tachometer does not operate. 1. Meter Circuit 2. Igniter 3. Wire Harness BE−32 − − Voltmeter does not operate. 1. Voltmeter Receiver Gauge 2. Wire Harness No.1 Vehicle Speed Sensor Speedometer Driven Gear and Drive Gear Meter Circuit Wire Harness 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 AT−6 − Brought to you by BirfMark BE−5 BODY ELECTRICAL − BODY ELECTRICAL SYSTEM Fuel gauge does not operate or abnormal operation. 1. 2. 3. 4. Fuel Receiver Gauge Fuel Sender Gauge Meter Circuit Wire Harness BE−34 BE−34 BE−32 − Engine coolant temperature gauge does not operation or abnormal operate. 1. 2. 3. 4. Engine Coolant Temperature Receiver Gauge Engine Coolant Temperature Sender Gauge Meter Circuit Wire Harness BE−34 BE−34 BE−32 − Oil pressure gauge does not operate or abnormal operation. 1. 2. 3. 4. Oil Pressure Receiver Gauge Oil Pressure Sender Gauge Meter Circuit Wire Harness BE−34 BE−34 BE−34 − All illumination lights do not light up. 1. TAIL Fuse (I/P F/B) 2. Light Control Rheostat 3. Wire Harness Brightness does not change even when rheostat turned. 1. Bulb 2. Wire Harness − − Only one illumination light does not light up. 1. Bulb 2. Wire Harness − − − BE−34 − WARNING LIGHTS: COMBINATION METER Symptom Suspect Area See page Warning lights do not lights up. (Except discharge, SRS and door open) 1. GAUGE Fuse (I/P F/B) 2. Meter Circuit 3. Wire Harness − BE−32 − Brake warning light does not light up. 1. 2. 3. 4. 5. Bulb Brake Fluid Level Switch Parking Brake Switch Meter Circuit Wire Harness − BE−34 BE−34 BE−32 − Open door warning light does not light up. 1. 2. 3. 4. 5. Bulb Door Courtesy Switch DOME Fuse (No.2 R/B) Meter Circuit Wire Harness − BE−21 BE−21 − − − SRS warning light does not light up 1. 2. 3. 4. 5. Bulb Airbag Sensor Assembly ECU−B Fuse (I/P F/B) Meter Circuit Wire Harness − − − BE−32 − Discharge warning light does not light up. 1. 2. 3. 4. 5. Bulb IGN Fuse (No.1 J/B) Generator Meter Circuit Wire Harness − − − BE−32 − Seat belt warning light does not light up. 1. 2. 3. 4. 5. Bulb Seat Belt Buckle Switch Seat Belt Warning Relay (I/P F/B) Meter Circuit Wire Harness − BE−34 − BE−32 − 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BE−6 BODY ELECTRICAL − BODY ELECTRICAL SYSTEM Engine oil level warning light does not light up. 1. 2. 3. 4. Bulb Meter Circuit Engine Oil Level Warning Switch Wire Harness − BE−32 BE−34 − Low oil pressure warning light does not light up. 1. 2. 3. 4. Bulb Low Oil Pressure Warning Switch Meter Circuit Wire Harness − BE−32 BE−34 − Fuel level warning light does not light up. 1. 2. 3. 4. Bulb Fuel Level Warning Switch Meter Circuit Wire Harness − BE−34 BE−32 − INDICATOR LIGHTS: COMBINATION METER Symptom Suspect Area See page High beam indicator light does not light up. 1. 2. 3. 4. Bulb Headlight and Taillight System Meter Circuit Wire Harness − BE−19 BE−32 − Shift indicator lights do not light up. (ALL) 1. 2. 3. 4. Shift Position Indicator Wiring Circuit Park/Neutral Position Switch Wire Harness Bulb − BE−34 AT−6 − Shift indicator lights do not light up. (L, 2, D) 1. 2. 3. 4. 5. Bulb Shift Position Indicator Wiring Circuit Park/Neutral Position Switch Light Control Rheostat Wire Harness − BE−34 AT−6 BE−34 − Shift indicator lights do not light up. (PWR) 1. 2. 3. 4. Bulb Shift Position Indicator Wiring Circuit Pattern Select Switch Wire Harness − BE−34 AT−6 − Shift indicator lights do not light up. (2nd START) 1. 2. 3. 4. Bulb Shift Position Indicator Wiring Circuit ECM Wire Harness − AT−6 − − Only one shift indicator does not light up. 1. Bulb 2. Shift Position Indicator Wiring Circuit Indicator lights do not light up. (Except Turn, Hi−beam) 1. GAUGE Fuse (I/P F/B) 2. Wire Harness O/D OFF indicator light does not light up. 1. 2. 3. 4. Malfunction indicator light does not light up. 1. Bulb 2. ECM 3. Wire Harness Cruise control indicator light does not light up. 1. 2. 3. 4. Bulb O/D Main Switch Meter Circuit Wire Harness Bulb Cruise Control ECU Meter Circuit Wire Harness 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 − BE−34 − − − − BE−32 − − − − − − BE−32 − Brought to you by BirfMark BE−7 BODY ELECTRICAL − BODY ELECTRICAL SYSTEM DEFOGGER SYSTEM Symptom Suspect Area 1. 2. 3. 4. 5. 6. Defogger system does not operate. DEFOG Fuse (I/P F/B) GAUGE Fuse (I/P F/B) Defogger Switch Defogger Relay (No.1 R/B) Defogger Wire Wire Harness See page − − BE−43 BE−43 − − POWER WINDOW CONTROL SYSTEM Symptom Suspect Area See page Power window does not operate (ALL). (Power door lock does not operate.) 1. 2. 3. 4. POWER Fuse (I/P F/B) GAUGE Fuse (I/P F/B) Power Main Relay (No.1 R/B) Wire Harness − − − − Power window does not operate (ALL). (Power door lock is normal.) 1. 2. 3. 4. Ignition Switch Power Main Relay (No.1 R/B) Power Window Master Switch Wire Harness BE−11 − BE−46 − ”One touch power window system” does not operate. 1. Power Window Master Switch BE−46 Only one window glass does not operate. 1. 2. 3. 4. BE−46 BE−46 BE−46 − Power Window Master Switch Power Window Switch Power Window Motor Wire Harness POWER DOOR LOCK CONTROL SYSTEM Symptom Suspect Area See page Power door lock control system does not operate (ALL). 1. POWER Fuse (I/P F/B) 2. Power Main Relay (No.1 R/B) 3. Wire Harness − − − Power door lock control system does not operate by door lock control switch. 1. Door Lock Control Switch 2. Power Main Relay (No.1 R/B) 3. Wire Harness BE−51 − − Power door lock control system does not operate by door key. 1. Door Key Lock and Unlock Switch 2. Power Main Relay (No.1 R/B) 3. Wire Harness BE−11 − − Only one door does not operate. 1. Door Lock MotDor 2. Door Lock Link Disconnected 3. Wire Harness BE−51 − − Fault in key confine prevention operation. 1. 2. 3. 4. − BE−11 BE−21 − Power Main Relay (No.1 R/B) Key Unlock Warning Switch Door Courtesy Switch Wire Harness SLIDING ROOF SYSTEM Symptom Sliding roof system does not operate. (Door lock does not operate.) Suspect Area 1. 2. 3. 4. 5. 6. 7. 8. GAUGE Fuse (I/P F/B) Ignition Switch POWER Fuse (No.1 J/B) Power Main Relay (No.1 R/B) Sliding Roof Control Switch Sliding Roof Control Relay Sliding Roof Motor Wire Harness 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 See page − BE−11 − − BE−58 BE−58 BE−58 − Brought to you by BirfMark BE−8 BODY ELECTRICAL Sliding roof system operates abnormally. Sliding roof system stops operation half way. ”Key−off sliding roof” operation does not operate. − BODY ELECTRICAL SYSTEM 1. Limit Switch 2. Sliding Roof Control Switch 3. Sliding Roof Control Relay BE−58 BE−58 BE−58 1. 2. 3. 4. Sliding Roof Control Relay Sliding Roof Limit Switch Sliding Roof Control Switch Sliding Roof Motor (Stones to foreign material trapped in motor assembly) BE−58 BE−58 BE−58 BE−58 1. 2. 3. 4. 5. 6. POWER Fuse (I/P F/B) Door Lock Control Relay GAUGE Fuse (I/P F/B) Ignition Switch Door Courtesy Switch Wire Harness − BE−51 − BE−11 BE−21 − POWER MIRROR SYSTEM Symptom Suspect Area See page Power mirror system does not operate. 1. 2. 3. 4. CIG Fuse (I/P J/B) Mirror Control Switch Mirror Motor Wire Harness − BE−69 BE−69 − Power mirror operate abnormally. 1. Mirror Control Switch 2. Mirror Motor 3. Wire Harness BE−69 BE−69 − POWER SEAT CONTROL SYSTEM Symptom Suspect Area See page Power seat does not operate. 1. POWER Fuse (I/P F/B) 2. Power Seat Switch 3. Wire Harness − BE−62 − ”Sliding operation” does not operate. 1. Slide Motor 2. Power Seat Switch 3. Wire Harness BE−62 BE−62 − ”Reclining operation” does not operate. 1. Reclining Motor 2. Power Seat Switch 3. Wire Harness BE−62 BE−62 − ”Rear vertical operation” does not operate. 1. Rear Vertical Motor 2. Power Seat Switch 3. Wire Harness BE−62 BE−62 − ”Lumber support operation” does not operate. 1. Lumber Support Motor 2. Lumber Support Switch 3. Wire Harness BE−62 BE−62 − 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BE−9 BODY ELECTRICAL − POWER SOURCE POWER SOURCE BE1LU−01 LOCATION 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 1147 Brought to you by BirfMark BE−10 BODY ELECTRICAL − IGNITION SWITCH AND KEY UNLOCK WARNING SWITCH IGNITION SWITCH AND KEY UNLOCK WARNING SWITCH BE1LV−01 LOCATION 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 1148 Brought to you by BirfMark BODY ELECTRICAL − IGNITION SWITCH AND KEY UNLOCK WARNING SWITCH BE1LW−01 INSPECTION 1. BE−11 INSPECT IGNITION SWITCH CONTINUITY Switch position Tester connection Specified condition LOCK − ACC 7−9 Continuity ON 3 − 4, 6 − 7 − 9 Continuity START 2−3−4 6 − 9 − 10 Continuity No continuity If continuity is not as specified, replace the switch. 2. INSPECT SWITCH CONTINUITY Condition Tester connection SW OFF (Key removed) − SW ON (Key set) 1−5 Specified condition No continuity Continuity If continuity is not as specified, replace the switch. 3. INSPECT DOOR COURTESY SWITCH CONTINUITY (See page BE−21) 4. INSPECT SEAT BELT WARNING RELAY CIRCUIT (See page BE−34) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BE−12 BODY ELECTRICAL − HEADLIGHT AND TAILLIGHT SYSTEM HEADLIGHT AND TAILLIGHT SYSTEM BE1LX−01 LOCATION 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 1150 Brought to you by BirfMark BE−13 BODY ELECTRICAL − HEADLIGHT AND TAILLIGHT SYSTEM BE1LY−01 COMPONENTS 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BE−14 BODY ELECTRICAL − HEADLIGHT AND TAILLIGHT SYSTEM BE1LZ−01 INSPECTION 1. INSPECT LIGHT CONTROL SWITCH CONTINUITY Switch position Tester connection Specified condition OFF − TAIL A2 − A11 Continuity HEAD A2 − A11 − A13 Continuity No continuity If continuity is not as specified, replace the switch. 2. INSPECT HEADLIGHT DIMMER SWITCH CONTINUITY Switch position Tester connection Flash A9 − A12 − A14 Continuity Specified condition Low beam A3 − A9 Continuity High beam A9 − A12 Continuity If continuity is not as specified, replace the switch. 3. INSPECT HEADLIGHT CONTROL RELAY CONTINUITY Condition Tester connection Specified condition Constant 1−2 Continuity Apply B+ between terminals 1 and 2. 3−4 Continuity If continuity is not as specified, replace the relay. 4. INSPECT TAILLIGHT CONTROL RELAY CONTINUITY Condition Tester connection Specified condition Constant 1−2 Continuity Apply B+ between terminals 1 and 2. 2−3 Continuity If continuity is not as specified, replace the relay. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BE−15 BODY ELECTRICAL 5. (a) (b) (c) − HEADLIGHT AND TAILLIGHT SYSTEM INSPECT HEADLIGHT RETAINER CIRCUIT Connect the positive (+) leads from the battery to terminals 1 and 6, and the negative (−) lead to terminal 3. Connect the 3.4 W test bulb between terminal 7 and the positive (+) lead from the battery. Disconnect the positive (+) lead from terminal 1, and check that the test bulb is lighting. (d) Connect the negative (−) lead to terminal 5, and check that the test bulb goes out. If operation is not as specified, replace the relay. 6. (a) (b) (c) INSPECT TAILLIGHT CIRCUIT Connect the positive (+) leads from the battery to terminals 1 and 6, and the negative (−) lead to terminal 2. Connect the 3.4 W test bulb between terminal 8 and the positive (+) lead from the battery. Disconnect the positive (+) lead from terminal 1, and check that the test bulb is lighting. (d) Connect the negative (−) lead to terminal 5, and check that the test bulb goes out. If operation is not as specified, replace the relay. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BE−16 BODY ELECTRICAL − HEADLIGHT AND TAILLIGHT SYSTEM ADJUSTMENT 1. (a) BE1M0−01 ADJUSTING HEADLIGHT AIM ONLY Put the vehicle in below conditions. S Make sure the body around the headlight is not deformed. S Park the vehicle on a level place. S The driver gets into the driver’s seat and puts the vehicle in a state ready for driving (with a full tank). S Bounce the vehicle several times. (b) Adjust headlight in vertical alignment. If the gauge bubble is outside the acceptable range of the beam angle gauge, adjust it using adjusting screw A. HINT: The beam angle will change about 0°11’ with one mark. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BE−17 BODY ELECTRICAL − HEADLIGHT AND TAILLIGHT SYSTEM (c) Adjust headlight in horizontal alignment. If the ”0” moves away from the mark beyond the acceptable range, adjust the ”0” back to the mark using adjusting screw B. HINT: The beam angle will change about 0°23’ with one mark. 2. REPLACING HEADLIGHT (a) Replace the headlight. (b) Inspect the headlight aim. Do the following before inspection. S Make sure the body around the headlight is not deformed. S Park the vehicle on a level spot. S The driver gets into the driver’s seat and puts the vehicle in a state ready for driving (with a full tank). S Bounce the vehicle several times. (c) Adjust headlight in vertical alignment (1) Using adjusting screw A, adjust the headlight aim to within the specifications. HINT: The beam angle will change about 0°11’ with one mark. (2) Make sure the gauge bubble is within the acceptable range. HINT: If the gauge bubble is outside the acceptable range, check that the vehicle is parked on a level place. (d) Readjust the headlight aim after parking the vehicle on a level place. (e) Adjust the headlight in horizontal alignment. (1) Using adjusting screw B, adjust the headlight aim to within the specifications. HINT: The beam angle will change about 0°23’ with one mark. (2) Using adjusting nut C, adjust the ”0” back to the mark. HINT: For adjustment, pull nut C to the rear of the vehicle to free it. After adjustment, check that the nut C is locked in. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BE−18 BODY ELECTRICAL − TURN SIGNAL AND HAZARD WARNING SYSTEM TURN SIGNAL AND HAZARD WARNING SYSTEM BE1M1−01 LOCATION 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 1156 Brought to you by BirfMark BE−19 BODY ELECTRICAL − TURN SIGNAL AND HAZARD WARNING SYSTEM BE27G−01 INSPECTION 1. INSPECT HAZARD WARNING SWITCH CONTINUITY Condition Tester connection Specified condition Switch OFF 7 − 10 Continuity Switch ON 7−8 4−5−6−9 Continuity Illumination circuit 2−3 Continuity If continuity is not as specified, replace the switch. 2. (a) (b) BE1843 INSPECT TURN SIGNAL FLASHER OPERATION Connect the positive (+) lead from the battery to terminal 2 and the negative (−) lead to terminal 3. Connect the 2 turn signal light bulbs parallel to each other to terminals 1 and 3, and check that the bulbs flash. HINT: The turn signal lights should flash 60 to 120 times per minute. If one of the front or rear turn signal lights has an open circuit, the number of flashes will be more than 140 per minute. If operation is not as specified, replace the flasher. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BE−20 BODY ELECTRICAL − INTERIOR LIGHT SYSTEM INTERIOR LIGHT SYSTEM BE1M3−01 LOCATION 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 1158 Brought to you by BirfMark BE−21 BODY ELECTRICAL − INTERIOR LIGHT SYSTEM BE1M4−01 INSPECTION 1. INSPECT GLOVE BOX LIGHT SWITCH CONTINUITY Switch position Tester connection OFF (Closed) − ON (Opened) 1−2 Specified condition No continuity Continuity If continuity is not as specified, replace the switch. 2. (a) INSPECT DOOR COURTESY SWITCH CONTINUITY Check that there is continuity between terminal and the switch body with the switch ON (switch pin released: opened door). (b) Check that there is no continuity between terminal and the switch body with the switch OFF (switch pin pushed in: closed door). If operation is not as specified, replace the switch. ON OFF BE1428 3. INSPECT FRONT PERSONAL LIGHT CONTINUITY Switch position Tester connection OFF − ON 5−6 Specified condition No continuity Continuity If continuity is not as specified, replace the personal light. 4. (a) (b) INSPECT ROOM LIGHT ASSEMBLY Disconnect the connector from room light assembly. Turn the room light switch ON, check that there is continuity between terminal 2 and body ground. (c) Turn the room light switch DOOR, and check that there is continuity between terminal 1 and 2. If operation is not as specified, replace the switch. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BE−22 BODY ELECTRICAL − BACK−UP LIGHT SYSTEM BACK−UP LIGHT SYSTEM BE1M5−01 LOCATION 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 1160 Brought to you by BirfMark BE−23 BODY ELECTRICAL − BACK−UP LIGHT SYSTEM BE1M6−01 INSPECTION INSPECT PARK/NEUTRAL POSITION SWITCH CONTINUITY (See page AT−6) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BE−24 BODY ELECTRICAL − STOP LIGHT SYSTEM STOP LIGHT SYSTEM BE1M7−01 LOCATION 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 1162 Brought to you by BirfMark BE−25 BODY ELECTRICAL − STOP LIGHT SYSTEM BE1M8−01 INSPECTION INSPECT STOP LIGHT SWITCH CONTINUITY Switch position Tester connection SW pin free 1−2 SW pin pushed in − Specified condition Continuity No continuity If continuity is not as specified, replace the switch. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BE−26 BODY ELECTRICAL − WIPER AND WASHER SYSTEM WIPER AND WASHER SYSTEM BE1M9−01 LOCATION 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 1164 Brought to you by BirfMark BE−27 BODY ELECTRICAL − WIPER AND WASHER SYSTEM BE1MA−01 INSPECTION 1. INSPECT FRONT WIPER AND WASHER SWITCH CONTINUITY Switch position Tester connection Specified condition Wiper OFF B4 − B7 Continuity Wiper INT B4 − B7 Continuity Wiper LO B7 − B18 Continuity Wiper HI B13 − B18 Continuity Washer OFF − Washer ON B8 − B16 No continuity Continuity If continuity is not as specified, replace the switch. 2. INSPECT REAR WIPER AND WASHER SWITCH CONTINUITY Switch position Tester connection Washer ON B2 − B16 Specified condition Continuity Wiper OFF − Wiper INT B10 − B16 No continuity Continuity Wiper ON B1 − B16 Continuity Washer ON B1 − B2 − B16 Continuity If continuity is not as specified, replace the switch. B7 B16 3. (a) (b) (c) INSPECT INTERMITTENT WIPER OPERATION Turn the wiper switch to INT position. Turn the intermittent time control switch to FAST position. Connect the positive (+) lead from the battery to terminal B18 and the negative (−) lead to terminal B16. (d) Connect the positive (+) lead from the voltmeter to terminal B7 and the negative (−) lead to terminal B16, and check that the meter needle indicates battery positive voltage. After connecting terminal B4 to termianl B18, connect B18 to terminal B16. Then, check that the voltage rises from O volt to battery positive voltage within time as follows. B18 B7 B4 (e) B18 B16 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BE−28 BODY ELECTRICAL − WIPER AND WASHER SYSTEM 3.3 ± 1 sec. Battery Positive Voltage V02744 If operation is not as specified, replace the switch. B7 B16 4. (a) (b) (c) B18 INSPECT WASHER LINKED OPERATION Connect the positive (+) lead from the battery to terminal B18 and the negative (−) lead to terminal B16. Connect the positive (+) lead from the voltmeter to terminal B7 and the negative (−) lead to terminal B16. Push in the washer switch. Check that the voltage changes, as shown in the table. Washer Switch ON Batt eryposit ive voltage 0V Approx. 0.5 sec. Approx. 2.5 sec. OFF V02745 If operation is not as specified, replace the switch. 5. (a) INSPECT REAR WIPER RELAY CONTINUITY Check that there is no continuity between terminals 1 and 3. (b) Check that there is continuity between terminals 2 and 3. If continuity is not as specified, replace the relay. 6. (a) INSPECT REAR WIPER RELAY OPERATION Connect the positive (+) lead from the battery to terminal 1 and the negative (−) lead to terminal 6. (b) Connect the positive (+) lead from the voltmeter to terminal 2 and the negative (−) lead to terminal 6, and check that the meter needle indicates to O V. (c) Connect the positive (+) lead from the voltmeter to terminal 3 and the negative (−) lead to terminal 6, and check that the meter needle indicates to battery positive voltage. If operation is not as specified, replace the relay. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BE−29 BODY ELECTRICAL − WIPER AND WASHER SYSTEM 7. INSPECT REAR WIPER RELAY INTERMITTENT OPERATION (a) Connect the positive (+) lead from the battery to terminal 2 and the negative (−) lead to terminal 4. (b) Connect the positive (+) lead from the voltmeter to terminal 3 and the negative (−) lead to terminal 4. (c) After disconnecting the positive (+) lead from terminal 2, connect it to terminal 1, and then, check that the meter needle rises from O V to battery positive voltage within 6 to 10 seconds. If operation is not as specified, replace the relay. 8. Low Speed: INSPECT FRONT WIPER MOTOR OPERATION Connect the positive (+) lead from the battery to terminal 3 and negative (−) lead to terminal 1, and check that the motor operates at low speed. If operation is not as specified, replace the motor. 9. High Speed: INSPECT FRONT WIPER MOTOR OPERATION Connect the positive (+) lead from the battery to terminal 2 and the negative (−) lead to terminal 1, and check that the motor operates at high speed. If operation is not as specified, replace the motor. 10. (a) Stopping at Stop Position: INSPECT FRONT WIPER MOTOR OPERATION Operate the motor at low speed and stop the motor operation anywhere except at the stop position by disconnecting positive (+) lead from terminal 3. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BE−30 BODY ELECTRICAL − WIPER AND WASHER SYSTEM (b) (c) Connect terminal 3 and 5. Connect the positive (+) lead from the battery to terminal 6 and the negative (−) lead to terminal 1, and check that the motor stops running at the stop position after the motor operates again. If operation is not as specified, replace the motor. 11. Low Speed: INSPECT REAR WIPER MOTOR OPERATION Connect the positive (+) lead from the battery to terminal 3 and negative (−) lead to terminal 2, and check that the motor operates at low speed. If operation is not as specified, replace the motor. 12. (a) Stopping at Stop Position: INSPECT REAR WIPER MOTOR OPERATION Operate the motor at low speed and stop the motor operation anywhere except at the stop position by disconnecting positive (+) lead from terminal 3. (b) (c) Connect terminal 3 and 4. Connect the positive (+) lead from the battery to terminal 1 and the negative (−) lead to terminal 2, and check that the motor stops running at the stop position after the motor operates again. If operation is not as specified, replace the motor. 13. INSPECT WASHER MOTOR OPERATION Connect the positive (+) lead from the battery to terminal 2 and the negative (−) lead to terminal 1, and check that the motor operates. NOTICE: These tests must be performed quickly (within 20 seconds) to prevent the coil from burning out. If operation is not as specified, replace the motor. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BE−31 BODY ELECTRICAL − COMBINATION METER COMBINATION METER BE1MB−01 LOCATION 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 1169 Brought to you by BirfMark BE−32 BODY ELECTRICAL − COMBINATION METER BE1MC−01 CIRCUIT 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BE−33 BODY ELECTRICAL − COMBINATION METER 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BE−34 BODY ELECTRICAL − COMBINATION METER BE1MD−01 INSPECTION 1. INSPECT SPEEDOMETER ON−VEHICLE: Using a speedometer tester, inspect the speedometer for allowable indication error and check the operation of the odometer. HINT: Tire wear and tire over or under inflation will increase the indication error. If error is excessive, replace the speedometer. 2. (a) (b) (c) (d) Standard indication Allowable range 20 18 − 24 40 38 − 44 60 58 − 66 80 78 − 88 100 98 − 110 120 118 − 132 INSPECT NO.1 VEHICLE SPEED SENSOR OPERATION Connect the positive (+) lead from battery to terminal 1 and negative (−) lead to terminal 2. Connect the positive (+) lead from tester to terminal 3 and the negative (−) lead to terminal 2. Revolve shaft. Check that there is voltage changer from approx. 0 V to 11 V or more between terminals 3 and 2. HINT: The voltage change should be 4 times per each revolution of the No.1 vehicle speed sensor shaft. If operation is not as specified, replace the sensor. 3. INSPECT TACHOMETER ON−VEHICLE: (a) Connect a tune−up test tachometer, and start the engine. NOTICE: Reversing the connection of the tachometer will damage the transistors and diodes inside.When removing or installing the tachometer, be careful not to drop or subject it to heavy shocks. (b) Compare the tester and tachometer indications. If error is excessive, replace the tachometer. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BE−35 BODY ELECTRICAL − COMBINATION METER RPM (DC 13.5 V, 25°C (77 °F)) Standard indication Allowable range 700 630 − 770 1,000 900 − 1,100 2,000 1,875 − 2,125 3,000 2,850 − 3,150 4,000 3,850 − 4,150 5,000 4,850 − 5,150 4. INSPECT VOLTMETER ON−VEHICLE: Compare the tester and voltmeter indications. If error is excessive, replace the voltemeter. 5. (a) (b) INSPECT FUEL RECEIVER GAUGE OPERATION Disconnect the connector from the sender gauge. Turn the ignition switch ON, and check that the receiver gauge needle indicates EMPTY. (c) Connect terminals 4 and 5 on the wire harness side connector through a 3.4 W test bulb. Turn the ignition switch ON, and check that the bulb lights up and the receiver gauge needle moves towards the full side. (d) HINT: Because of the silicon oil in the gauge, it will take a short time for needle to stabilize. If operation is not as specified, inspect the receiver gauge resistance. 6. INSPECT FUEL RECEIVER GAUGE RESISTANCE Between terminals Resistance (Ω) A−B 85.5 − 105.5 A−C 126 − 150 B−C *90 − 110 *: Include voltmeter resistance If resistance value is not as specified, replace the fuel receiver gauge. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BE−36 BODY ELECTRICAL 7. (a) (b) (c) (d) − COMBINATION METER INSPECT FUEL SENDER GAUGE OPERATION Connect a series of three 1.5 V dry cell batteries. Connect the positive (+) lead from the dry cell batteries to terminal 4 through a 3.4 W test bulb and the negative (−) lead to terminal 5. Connect the positive (+) lead from the voltmeter to terminal 4 and the negative (−) lead to terminal 5. Check that the voltage rises as the float is moved from the full to empty position. 8. INSPECT FUEL SENDER GAUGE RESISTANCE Measure the resistance between terminals 4 and 5. Float position: mm (in.) Resistance (Ω) F: Approx. 15.0 (0.591) Approx. 3.0 E: Approx. 200.0 (7.874) Approx. 110.0 If resistance value is not as specified, replace the sender gauge. 9. (a) (b) INSPECT FUEL LEVEL WARNING LIGHT Disconnect the connector from the sender gauge. Connect terminals 1 and 5 on the wire harness side connector. (c) Turn the ignition switch ON, and check that the warning light lights up. If the warning light does not light up, test the bulb. 10. (a) INSPECT FUEL LEVEL WARNING SWITCH Apply battery positive voltage between terminals 1 and 5 through a 3.4 W test bulb, and check that the bulb lights up. HINT: It will take a short time for the bulb to light up. (b) Submerge the switch in fuel, and check that the bulb goes out. If operation is not as specified, replace the sender gauge. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BE−37 BODY ELECTRICAL Ignition Switch Engine Coolant Temperature Gauge (a) (b) Sender Gauge Battery COMBINATION METER INSPECT ENGINE COOLANT TEMPERATURE RECEIVER GAUGE OPERATION Disconnect the connector from the sender gauge. Turn the ignition switch ON, and check that the receiver gauge needle indicates COOL. (c) Ground terminal on the wire harness side connector through a 3.4 W test bulb. (d) Turn the ignition switch ON, and check that the bulb lights up and the receiver gauge needle moves to the hot side. If operation is as specified, replace the sender gauge. Then recheck the system. If operation is not as specified, measure the receiver gauge resistance. Engine Coolant Temperature Gauge Ignition Switch 11. − Tester Bulb (3.4 W) Battery Z06815 12. INSPECT ENGINE COOLANT TEMPERATURE RECEIVER GAUGE RESISTANCE Measure the resistance between terminals. Between terminals Resistance (Ω) A−B 71 − 79 A−C 117 − 141 B−C 185 − 215 HINT: Connect the test leads so that the current from the ohmmeter can flow according to the above order. This circuit include the diode. If resistance value is not as specified, replace the receiver gauge. 13. Oil Pressure Gauge I g n i t i on Switch Battery (a) (b) Sender Gauge INSPECT OIL PRESSURE RECEIVER GAUGE OPERATION Disconnect the connector from the sender gauge. Turn the ignition switch ON, and check that the receiver gauge needle indicates LOW. BE1222 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BE−38 BODY ELECTRICAL − COMBINATION METER (c) Ground terminal on the wire harness side through a 3.4 W test bulb. (d) Turn the ignition switch ON, and check that the bulb lights up and that the receiver gauge needle moves to the high side. If operation is not as specified, measure the receiver gauge resistance. 14. INSPECT OIL PRESSURE RECEIVER GAUGE RESISTANCE Measure the receiver gauge resistance between terminals. Resistance: 40 − 48 Ω If resistance value is not as specified, replace the receiver gauge. 15. Test LED Battery BE4917 Warning Light I g n i t i on Switch Battery INSPECT OIL PRESSURE SENDER GAUGE OPERATION (a) Disconnect the connector from the sender gauge. (b) Apply battery positive voltage to the sender gauge terminal through a test LED. (c) Check that the bulb does not light when the engine is stopped. (d) Check that the LED flashes when the engine is running. The number of flashed should vary with engine speed. If operation is not as specified, replace the sender gauge. 16. INSPECT BRAKE WARNING LIGHT (a) Disconnect the connectors from the level warning switch and parking brake switch. (b) Connect terminals on the wire harness side connector of the level warning switch connector. (c) Turn the ignition switch ON, and check that the warning light lights up. BE1217 17. (a) INSPECT PARKING BRAKE SWITCH Check that there is continuity between terminal and the switch set nut with switch pin released (parking brake lever pulled up). (b) Check that there is no continuity between terminal and the switch set nut with switch pin pushed in. (parking brake lever released) If operation is not as specified, replace the switch. N01212 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BE−39 BODY ELECTRICAL − COMBINATION METER 18. (a) ON INSPECT BRAKE FLUID LEVEL WARNING SWITCH Check that there is no continuity between terminals with the switch OFF (float up). (b) Check that there is continuity between terminals with the switch ON (float down). If operation is not as specified, replace the switch. OFF BE2570 19. (a) INSPECT OPEN DOOR WARNING LIGHT Disconnect the connector from the door courtesy switch and ground terminal on the wire harness side connector. (b) Turn the ignition switch ON, and check that the warning light lights up. If the warning light does not light up, test the bulb. BE0044 20. (a) INSPECT DOOR COURTESY SWITCH Check that there is continuity between terminal and the switch body with the switch ON (switch pin released:opened door). (b) Check that there is no continuity between terminal and the switch body with the switch OFF (switch pin pushed in:closed door). If operation is not as specified, replace the switch. BE1428 21. (a) INSPECT SEAT BELT WARNING LIGHT Disconnect the connector from the seat belt warning relay. (b) Ground terminal 9 on the wire harness side connector. (c) Turn the ignition switch ON, and check that the warning light lights up. If the warning light does not light up, test the bulb. 22. (a) INSPECT SEAT BELT BUCKLE SWITCH CONTINUITY Check that there is continuity between terminals with the switch ON (belt unfastened). (b) Check that there is no continuity between terminals with the switch OFF (belt fastened). If operation is not as specified, replace the seat belt inner. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BE−40 BODY ELECTRICAL − COMBINATION METER 23. INSPECT SEAT BELT WARNING RELAY CIRCUIT Disconnect the connector from the relay and inspect the connector on the wire harness side, as shown in the chart. Tester connection Condition Specified condition 1 − Ground Constant Continuity 4 − Ground Driver’s seat belt position UNFASTEN Continuity 4 − Ground Driver’s seat belt position FASTEN No continuity 7 − Ground Ignition key SET Continuity 7 − Ground Ignition key Remove No continuity 8 − Ground Driver’s door position OPEN Continuity 8 − Ground Driver’s door position CLOSE No continuity 5 − Ground Ignition switch position ON Battery positive voltage 5 − Ground Ignition switch position LOCK or ACC No voltage 9 − Ground Constant Battery positive voltage If circuit is as specified, try another relay. If the circuit is not as specified, check the circuits connected to other parts. 24. (a) (b) INSPECT ENGINE OIL LEVEL WARNING SWITCH Check that there is continuity between terminal with the switch each position. Heat the switch to above 60°C (140°F) in an oil bath. (c) Check that there is continuity between terminals with the switch ON (float up). (d) Check that there is no continuity between terminals with the switch OFF (float down). If operation is not as specified, replace the switch. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BE−41 BODY ELECTRICAL − COMBINATION METER 25. INSPECT ENGINE OIL LEVEL WARNING CIRCUIT Disconnect the switch connector and inspect the connector on wire harness side, as shown. Tester connection Condition Specified condition 2 − Ground Constant Continuity If continuity is not as specified, inspect the wire harness or ground point. 26. (a) (b) (c) INSPECT ENGINE OIL LEVEL WARNING LIGHT Disconnect the connector from the switch. Ground terminal 1 on the wire harness connector. Turn the ignition switch ON, and check that the warning light lights up approximately 40 seconds later. If the warning light does not light up, inspect bulb or wire harness. Bright 1 Extinguished 3 2 Dark Z06300 27. (a) (b) INSPECT LIGHT CONTROL RHEOSTAT Connect terminals 1 and 3 through a 3.4 W test bulb. Connect the positive (+) lead from the battery to terminal 1 and the negative (−) lead to terminal 2. (c) Turn the rheostat knob to fully counterclockwise, and check that the test bulb goes out. (d) Gradually turn the rheostat knob to clockwise, and check that the test bulb brightness changes from dark to bright. If operation is not as specified, replace the rheostat. HINT: Adjust the brightness of illumination lights by rheostat. S A/C Control Assembly S Antenna Switch S Ash Receptacle S Audio S Center Diff. Lock Switch S Cigarette Lighter S Defogger Switch S Hazard Warning Switch S Shift Lever 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BE−42 BODY ELECTRICAL − DEFOGGER SYSTEM DEFOGGER SYSTEM BE1ME−01 LOCATION 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 1180 Brought to you by BirfMark BE−43 BODY ELECTRICAL − DEFOGGER SYSTEM BE1MF−01 INSPECTION 1. INSPECT DEFOGGER SWITCH CONTINUITY Condition Tester connection Specified condition Switch OFF − Switch ON 2−3−6 Continuity Illumination circuit 1−4 Continuity No continuity If continuity is not as specified, check the bulb or replace the switch. 2. INSPECT DEFOGGER RELAY CONTINUITY (See page BE−46.) Tester Plobe Heat Wire Tin Foil BE4029 At Center BE0123 0V Several 3. INSPECT DEFOGGER WIRES NOTICE: When cleaning the glass, use a soft, dry cloth and wipe the glass in the direction of the wire. Take care not to damage the wires.Do not use detergents or glass cleaners with abrasive ingredients.When measuring voltage, wind a piece of tin foil around the top of the negative (−) probe and press the foil against the wire with your finger, as shown. (a) Turn the ignition switch ON. (b) Turn the defogger switch ON. (c) Inspect the voltage at the center of each heat wire, as shown. Criteria Approx. 5V Okay (No break in wire) Approx.10V or 0V Broken wire HINT: If there is 10 V, the wire is broken between the center of the wire and positive (+) end. If there is no voltage, the wire is broken between the center of the wire and ground. (d) (e) Broken Wire Voltage Place the voltmeter positive (+) lead against the defogger positive (+) terminal. Place the voltmeter negative (−) lead with the foil strip against the heat wire at the positive (+) terminal end and slide it toward the negative (−) terminal end. BE0124 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BE−44 BODY ELECTRICAL (f) − DEFOGGER SYSTEM The point where the voltmeter deflects from zero to several V is the place where the heat wire is broken. HINT: If the heat wire is not broken, the voltmeter indicates 0 V at the positive (+) end of the heat wire but gradually increases to about 12 V as the meter probe is moved to the other end. 4. (a) Repair Point (b) Broken Wire IF NECESSARY, REPAIR DEFOGGER WIRE Clean the broken wire tips with a grease, wax and silicone remover. Place the masking tape along both sides of the wire to be repaired. Marking Tape BE0150 (c) (d) (e) (f) Thoroughly mix the repair agent (Dupont paste No. 4817 or equivalent). Using a fine tip brush, apply a small amount to the wire. After a few minutes, remove the masking tape. Do not repair the defogger wire for at least 24 hours. BE0151 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BE−45 BODY ELECTRICAL − POWER WINDOW CONTROL SYSTEM POWER WINDOW CONTROL SYSTEM BE1MG−01 LOCATION 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 1183 Brought to you by BirfMark BE−46 BODY ELECTRICAL − POWER WINDOW CONTROL SYSTEM BE1MH−01 INSPECTION 1. INSPECT POWER WINDOW MASTER SWITCH CONTINUITY Front Driver’s Switch (Window unlock): Switch position Tester connection Specified condition UP 1 − 2 − 13 6−7−8 Continuity OFF 1 − 2 − 6 − 13 Continuity DOWN 1−2−6 7 − 8 − 13 Continuity Front Driver’s Switch (Window lock): Z06846 Switch position Tester connection Specified condition UP 1 − 2 − 13 6−7−8 Continuity OFF 1 − 2 − 6 − 13 Continuity DOWN 1−2−6 7 − 8 − 13 Continuity Front Passenger’s Switch (Window unlock): Switch position Tester connection Specified condition UP 1−2−5 7 − 8 − 12 Continuity OFF 1 − 2 − 5 − 12 Continuity DOWN 1 − 2 − 12 5−7−8 Continuity Front Passenger’s Switch (Window lock): Switch position Tester connection UP 7 − 8 − 12 Continuity Specified condition OFF 5 − 12 Continuity DOWN 5−7−8 Continuity Rear Left Switch (Window unlock): Switch position Tester connection Specified condition UP 1−2−9 7 − 8 − 10 Continuity OFF 1 − 2 − 9 − 10 Continuity DOWN 1 − 2 − 10 7−8−9 Continuity Rear Left Switch (Window lock): Switch position Tester connection Specified condition UP 7 − 8 − 10 Continuity OFF 9 − 10 Continuity DOWN 7−8−9 Continuity Rear Right Switch (Window unlock): Switch position Tester connection UP 1 − 2 − 14 7 − 8 − 11 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Specified condition Continuity Brought to you by BirfMark BE−47 BODY ELECTRICAL − POWER WINDOW CONTROL SYSTEM OFF 1 − 2 − 11 − 14 DOWN 1 − 2 − 11 7 − 8 − 14 Continuity Continuity Rear Right Switch (Window lock): Switch position Tester connection Specified condition UP 7 − 8 − 11 Continuity OFF 11 − 14 Continuity DOWN 7 − 8 − 14 Continuity If continuity is not as specified, replace the master switch. 2. INSPECT POWER WINDOW MASTER SWITCH ILLUMINATION (a) Set the window lock switch to the unlock position. (b) Connect the positive (+) lead from the battery to terminal 7 and the negative (−) lead to terminal 1, and check that all the illuminations light up. (c) Set the window lock switch to the lock position, and check that all the passenger’s power window switch illuminations go out. If operation is not as specified, replace the master switch. 3. (a) (b) (c) (d) (e) Z06302 Using an ammeter: INSPECT ONE TOUCH POWER WINDOW SYSTEM Disconnect the connector from the master switch. Connect the positive (+) lead from the ammeter to terminal 6 on the wire harness side connector and the negative (−) lead to negative terminal of the battery. Connect the positive (+) lead from the battery to terminal 13 on the wire harness side connector. As the window goes down, check that the current flow is up to approximately 7 A. Check that the current increases approximately 14.5 A or more when the window stops going down. HINT: The circuit breaker opens some 4 − 40 seconds after the window stops going down, so that check must be made before the circuit breaker operates. If the operation is as specified, replace the master switch. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BE−48 BODY ELECTRICAL 4. (a) (b) (c) (d) Z06303 (e) − POWER WINDOW CONTROL SYSTEM Using an ammeter with a current − measuring probe: INSPECT ONE TOUCH POWER WINDOW SYSTEM Remove the master switch with connector connected. Attach a current−measuring probe to terminal 6 of the wire harness. Turn the ignition switch ON, and set the power window switch in the down position. As the window goes down, check that the current flow is up to approximately 7 A. Check that the current increases approximately 14.5 A or more when the window stops going down. HINT: The circuit breaker opens some 4 − 40 seconds after the window stops going down, so check must be made before the circuit breaker operates. If operation is as specified, replace the master switch. Z06304 5. INSPECT POWER WINDOW SWITCH CONTINUITY Switch position Tester connection Specified condition UP 1 − 5, 3 − 4 Continuity OFF 1 − 2, 3 − 4 Continuity DOWN 1 − 2, 4 − 5 Continuity If continuity is not as specified, replace the switch. 6. Front Door: INSPECT LEFT SIDE DOOR POWER WINDOW MOTOR OPERATION (a) Connect the positive (+) lead from the battery to terminal 3 and the negative (−) lead to terminal 1, and check that the motor turns clockwise. (b) Reverse the polarity, and check that the motor turns counterclockwise. If operation is not as specified, replace the motor. 7. Rear Door: INSPECT LEFT SIDE DOOR POWER WINDOW MOTOR OPERATION (a) Connect the positive (+) lead from the battery to terminal 1 and the negative (−) lead to terminal 2, and check that the motor turns counterclockwise. (b) Reverse the polarity, and check that the motor turns clockwise. If operation is not as specified, replace the motor. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BE−49 BODY ELECTRICAL 8. (a) (b) (c) Z06307 − POWER WINDOW CONTROL SYSTEM INSPECT DRIVER’S DOOR PTC OPERATION Disconnect the connector from the master switch. Connect the positive (+) lead from the battery to terminal 6 and the negative (−) lead to terminal 13 on the wire harness side connecter and raise the window to full closed position. Continue to apply voltage, check that the current changes from approximately 14 A to less that 1 A within 4 to 90 seconds. (d) (e) Disconnect the leads from terminals. After approximately 90 seconds, connect the positive (+) lead from the battery to terminal 13 and negative (−) lead to terminal 6, check that the window beginsto desced. If operation is not as specified, replace the motor. Z06308 9. (a) (b) 1 4 (c) Z06309 (d) INSPECT PASSENGER’S DOOR PTC OPERATION Disconnect the connector from the power window switch. Connect the positive (+) lead from the battery to terminal 1 and the negative (−) lead to terminal 4 on the wire harness side connector, and raise the window to full closed position. Connect the positive (+) lead from the battery to terminal 1 on the wire harness side connector. Disconnect the leads from terminals. (e) 1 4 After approximately 90 seconds, connect the positive (+) lead from the battery to terminal 4 and negative (−) lead to terminal 1, check that the window begins to descend. If operation is not as specified, replace the motor. Z06310 10. (a) (b) INSPECT PASSENGER’S DOOR MOTOR OPERATION Connect the positive (+) lead from the battery to terminal 1 and the negative (−) lead to terminal 3, and check that the motor turns clockwise. Reverse the polarity, and check that the motor turns counterclockwise. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BE−50 BODY ELECTRICAL − POWER WINDOW CONTROL SYSTEM 11. INSPECT REAR RIGHT SIDE DOOR MOTOR OPERAION (a) Connect the positive (+) lead from the battery to terminal 2 and the negative (−) lead to terminal 1, and check that the motor turns counterclockwise. (b) Reverse the polarity, and check that the motor turns clockwise. If operation is not as specified, replace the motor. 12. INSPECT RIGHT SIDE PTC OPERATION 13. INSPECT POWER MAIN RELAY CONTINUITY Condition Tester connection Specified condition Constant 1−3 Continuity Apply B+ between terminals 1 and 3. 2−4 Continuity If continuity is not as specified, replace the relay. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BE−51 BODY ELECTRICAL − POWER DOOR LOCK CONTROL SYSTEM POWER DOOR LOCK CONTROL SYSTEM BE1MI−01 LOCATION 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 1189 Brought to you by BirfMark BE−52 BODY ELECTRICAL − POWER DOOR LOCK CONTROL SYSTEM BE1MJ−01 INSPECTION 1. INSPECT DRIVER’S DOOR LOCK MANUAL SWITCH CONTINUITY Switch position Tester connection LOCK 1−2−4 OFF − UNLOCK 1−2−3 Specified condition Continuity No continuity Continuity If continuity is not as specified, replace the switch. Z06846 2. INSPECT DOOR KEY LOCK AND UNLOCK SWITCH CONTINUITY Switch position Tester connection LOCK 1−3 OFF − UNLOCK 2−3 Specified condition Continuity No continuity Continuity If continuity is not as specified, replace the switch. HINT: Door key lock and unlock switch is built into the front door lock assembly. 3. INSPECT KEY UNLOCK WARNING SWITCH CONTINUITY (See page BE−11) 4. INSPECT DOOR COURTESY SWITCH CONTINUITY (See page BE−21) 5. INSPECT DOOR LOCK MOTOR OPERATION 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BE−53 BODY ELECTRICAL − POWER DOOR LOCK CONTROL SYSTEM (a) Connect the positive (+) lead from the battery to terminal 2 and the negative (−) lead to terminal 4, and check that the door lock link moves to UNLOCK position. (b) Remove the polarity, and check that the door lock link move to LOCK position. If operation is not as specified, replace the door lock assembly. 6. (a) (b) Using an ammeter: INSPECT PTC THERMISTOR OPERATION Connect the positive (+) lead from the battery to terminal 2. Connect the positive (+) lead from the ammeter to terminal 4 and the negative (−) lead to battery negative (−) terminal, and check that the current changes from approximately 3.2 A to less than 0.5 A within 20 to 70 seconds. (c) (d) Disconnect the leads from terminals. After approximately 60 seconds, connect the positive (+) lead from the battery to terminal 4 and the negative (−) lead to terminal 2, and check that the door lock moves to LOCK position. If operation is not as specified, replace the door lock assembly. 7. (a) (b) Using an ammeter with a current−measuring probe: INSPECT PTC THERMISTOR OPERATION Connect the positive (+) lead from the battery to terminal 2 and the negative (−) lead to terminal 4. Attach a current−measuring probe to either the positive (+) lead or the negative (−) lead, and check that the current changes from approximately 3.2 A to less than 0.5 A within 20 to 70 seconds. (c) (d) Disconnect the leads from terminals. After approximately 60 seconds, reverse the polarity, and check that the door lock moves to LOCK position. If operation is not as specified, replace the door lock assembly. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BE−54 BODY ELECTRICAL 8. − POWER DOOR LOCK CONTROL SYSTEM INSPECT DOOR UNLOCK DETECTION SWITCH CONTINUITY Switch position Tester connection OFF (Door Lock set to LOCK) − ON (Door Lock set to UNLOCK) 1−3 Specified condition No continuity Continuity If continuity is not as specified, replace the door lock assembly. 9. INSPECT POWER MAIN RELAY CONTINUITY (See page BE−46) 10. INSPECT DOOR LOCK CONTROL RELAY CIRCUIT Disconnect the connector from the relay and inspect the connector on the wire harness side, as shown in the chart. Tester connection Condition 2 − Ground Driver’s door courtesy switch position OFF (Door closed) No continuity 2 − Ground Driver’s door courtesy switch position ON (Door opened) Continuity 5 − Ground Passenger’s door lock switch position OFF (Door locked) No continuity 5 − Ground Passenger’s door lock switch position ON (Door unlocked) Continuity 6 − Ground Driver’s door lock switch position OFF (Door locked) No continuity 6 − Ground Driver’s door lock switch position ON (Door unlocked) Continuity 7 − Ground Key unlock warning switch position OFF (Ignition Key Removed) No continuity 7 − Ground Key unlock warning switch position ON (Ignition Key Set) Continuity 9 − Ground Driver’s door key lock and unlock switch position OFF or LOCK (Door key free of turned to lock) No continuity 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Specified condition Brought to you by BirfMark BE−55 BODY ELECTRICAL − POWER DOOR LOCK CONTROL SYSTEM 9 − Ground Driver’s door key lock and unlock switch position UNLOCK (Door key turned to unlock) Continuity 10 − Ground Door lock manual switch position OFF or UNLOCK No continuity 10 − Ground Door lock manual switch position LOCK Continuity 11 − Ground Door lock manual switch and passenger’s door key lock and unlock switch position OFF or UNLOCK No continuity 11 − Ground Door lock manual switch and passenger’s door key lock and unlock switch position UNLOCK Continuity 12 − Ground Driver’s and passenger’s door key lock and unlock switch position OFF or UNLOCK (Door key free or turned to unlock) No continuity 12 − Ground Driver’s or passenger’s door key lock and unlock switch position LOCK (Door key turned to lock) Continuity 14 − Ground Passenger’s door courtesy switch position OFF (Door closed) No continuity 14 − Ground Passenger’s door courtesy switch position ON (Door opened) Continuity 16 − Ground Constant Continuity 1 − Ground Ignition switch position LOCK or ACC No voltage 1 − Ground Ignition switch position ON Battery positive voltage 8 − Ground Constant Battery positive voltage If circuit is as specified, inspect the door lock signal. If the circuit is not as specified, inspect the circuits connected to other parts. 11. INSPECT DOOR LOCK SIGNAL HINT: When the relay circuit is as specified, inspect the door lock signal. (a) Connect the connector to the relay. (b) Connect the positive (+) lead from the voltmeter to terminal 3 and the negative (−) lead to terminal 4. (c) Set the door lock manual switch to UNLOCK, and check that the voltage rises from 0 V to battery positive voltage for approximately 0.2 seconds. (d) Reverse the polarity of the voltmeter leads. (e) Set the door lock manual switch to LOCK, and check that the voltage rises from 0 V to battery positive voltage for approximately 0.2 seconds. If operation is not as specified, replace the relay. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BE−56 BODY ELECTRICAL − POWER DOOR LOCK CONTROL SYSTEM 12. NSPECT KEY−OFF POWER WINDOW SIGNAL HINT: When the relay circuit is as specified, inspect the key−off power window signal. (a) Connect the connector to the relay. (b) Connect the positive (+) lead from the voltmeter to terminal 15 and the negative (−) lead to terminal 16. (c) Close the door with ignition switch truned to LOCK or ACC, check that the meter needle indicates battery positive voltage. (d) Open the door, check that the meter needle indicates 0 V. (e) Turn the ignition switch ON, check that the meter needle indicate battery positive voltage again. If operation is not as specified, replace the relay. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BE−57 BODY ELECTRICAL − SLIDING ROOF SYSTEM SLIDING ROOF SYSTEM BE1MK−01 LOCATION 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 1195 Brought to you by BirfMark BE−58 BODY ELECTRICAL − SLIDING ROOF SYSTEM BE1ML−01 INSPECTION 1. INSPECT SLIDING ROOF SWITCH CONTINUITY Switch position Tester connection Specified condition SLIDE OPEN 3−4 SLIDE OFF − SLIDE CLOSE 4−6 Continuity TILT DOWN 2−4 Continuity TILT OFF − TILT UP 5−4 Continuity No continuity No continuity Continuity If continuity is not as specified, replace the switch. 2. INSPECT SLIDING ROOF LIMIT SWITCH CONTINUITY Switch position Tester connection No.1 limit switch OFF (SW pin released) − No.1 limit switch ON (SW pin pushed in) 1−5 No.2 limit switch OFF (SW pin released) − No.2 limit switch ON (SW pin pushed in) 4−5 Specified condition No continuity Continuity No continuity Continuity If continuity is not as specified, replace the switch. 3. (a) INSPECT SLIDING ROOF MOTOR OPERATION Connect the positive (+) lead from the battery to terminal 1 and the negative (−) lead to terminal 3, and check that the motor turns clockwise. (b) Reverse the polarity, and check that the motor turns to clockwise. If operation is not as specified, replace the motor. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BE−59 BODY ELECTRICAL 4. (a) − SLIDING ROOF SYSTEM INSPECT SLIDING ROOF MOTOR CIRCUIT BREAKER OPERATION With the sliding roof in the fully opened position, hold the sliding roof switch in ”OPEN” position and check that there is a circuit breaker operation noise within 4 to 40 seconds. (b) With the sliding roof in fully opened position, hold the sliding roof switch in ”CLOSE” position and check that the sliding roof begins to close within 60 seconds. If operation is not as specified, replace the motor. 5. (a) INSPECT SLIDING ROOF MOTOR WIRE CIRCUIT Check that there is continuity between terminals A2 and B2. (b) Check that there is continuity between terminals A3 and B3. (c) Check that there is continuity between terminals A6 and B1. If continuity is not as specified, replace the switch. 6. INSPECT SLIDING ROOF CONTROL RELAY CIRCUIT Disconnect the connector from the relay and inspect the connector on the wire harness side, as shown in the chart. Tester connection Condition Specified condition 1 − Ground Sliding roof control switch position (SLIDE) OFF or CLOSE No continuity 1 − Ground Sliding roof control switch position (SLIDE) OPEN Continuity 2 − Ground Sliding roof control switch position (SLIDE) OFF or OPEN No continuity 2 − Ground Sliding roof control switch position (SLIDE) CLOSE Continuity 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BE−60 BODY ELECTRICAL − SLIDING ROOF SYSTEM 3 − Ground Sliding roof control switch position (TILT) OFF or DOWN No continuity 3 − Ground Sliding roof control switch position (TILT) UP Continuity 4 − Ground Constant No continuity 4−5 Constant *1Continuity 5 − Ground Constant No continuity 7 − Ground Sliding roof control switch position (TILT) OFF or UP No continuity 7 − Ground Sliding roof control switch position (TILT) DOWN Continuity 8 − Ground No.1 limit switch position OFF (Sliding roof tilted up or open approx. 200 mm (7.87 in.)) No continuity 8 − Ground No.1 limit switch position ON (Except for conditions mentioned above) Continuity 9 − Ground No.2 limit switch position OFF (Sliding roof closed) No continuity 9 − Ground No.2 limit switch position ON (Sliding roof open) Continuity 11 − Ground Constant Continuity 6 − Ground Ignition switch position LOCK or ACC *2No voltage 6 − Ground Ignition switch position ON Battery positive voltage 12 − Ground Constant Battery positive voltage *1: There is resistance because this circuit is include motor. *2: Exceptions: During 60 second period after ignition switch ON → OFF (ACC) or until driver or passenger door is opened after ignition switch ON → OFF (ACC). If circuit is as specified, replace the relay. If circuit is not as specified, inspect the circuits connected to other parts. 7. INSPECT POWER MAIN RELAY CONTINUITY (See page BE−46) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BE−61 BODY ELECTRICAL − POWER SEAT CONTROL SYSTEM POWER SEAT CONTROL SYSTEM BE1MO−01 LOCATION 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 1199 Brought to you by BirfMark BE−62 BODY ELECTRICAL − POWER SEAT CONTROL SYSTEM BE1MP−01 INSPECTION 1. INSPECT POWER SEAT SWITCH (DRIVER’S SIDE) CONTINUITY Slide switch: Switch position Tester connection Specified condition FORWARD 5 − 10, 8 − 9 Continuity OFF 5−8−9 Continuity BACKWARD 5 − 9, 8 − 10 Continuity Front vertical switch: Switch position Tester connection UP 4 − 11, 10 − 12 Continuity Specified condition OFF 4 − 11 − 12 Continuity DOWN 4 − 12, 10 − 11 Continuity Rear vertical switch: Switch position Tester connection Specified condition UP 2 − 10, 6 − 7 Continuity OFF 2−6−7 Continuity DOWN 2 − 7, 6 − 10 Continuity Reclining switch: Switch position Tester connection Specified condition FORWARD 4 − 10, 7 − 9 Continuity OFF 4−7−9 Continuity BACKWARD 4 − 9, 7 − 10 Continuity Lumbar support switch: Switch position Tester connection Specified condition FORWARD 4 − 10, 7 − 9 Continuity OFF 4−7−9 Continuity BACKWARD 4 − 9, 7 − 10 Continuity If continuity is not as specified, replace the switch. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BE−63 BODY ELECTRICAL − POWER SEAT CONTROL SYSTEM 2. INSPECT POWER SEAT SWITCH (PASSENGER’S SIDE) CONTINUITY Slide switch: Switch position Tester connection Specified condition FORWARD 5 − 10, 8 − 9 Continuity OFF 5−8−9 Continuity BACKWARD 5 − 9, 8 − 10 Continuity Front vertical switch: Switch position Tester connection Specified condition UP 4 − 11, 10 − 12 Continuity OFF 4 − 11 − 12 Continuity DOWN 4 − 12, 10 − 11 Continuity Rear vertical switch: Switch position Tester connection Specified condition UP 2 − 10, 6 − 7 Continuity OFF 2−6−7 Continuity DOWN 2 − 7, 6 − 10 Continuity Reclining switch: Switch position Tester connection Specified condition FORWARD 4 − 10, 7 − 9 Continuity OFF 4−7−9 Continuity BACKWARD 4 − 9, 7 − 10 Continuity If continuity is not as specified, replace the switch. 3. (a) INSPECT SLIDE MOTOR OPERATION Connect the positive (+) lead from the battery to terminal 1 and the negative (−) lead to terminal 2, and check that the motor turns counterclockwise. (b) Reverse the polarity, and check that the motor turns clockwise. If operation is not as specified, replace the motor. 4. (a) (b) INSPECT SLIDE MOTOR CIRCUIT BREAKER OPERATION Connect the positive (+) lead and the negative (−) lead from the battery to slide motor connector (illustrated terminals), and slide the seat to front end position. Continue to apply voltage, check that there is a circuit breaker operation noise within 4 to 60 seconds. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BE−64 BODY ELECTRICAL − POWER SEAT CONTROL SYSTEM (c) Reverse the polarity, and check that the seat begins to move backwards within approximately 60 seconds. If operation is not as specified, replace the motor. 5. (a) INSPECT FRONT VERTICAL MOTOR OPERATION Connect the positive (+) lead from the battery to terminal 1 and the negative (−) lead to terminal 2, and check that the motor turns clockwise. (b) Reverse the polarity, check that the motor turns counterclockwise. If operation is not as specified, replace the motor. 6. (a) (b) INSPECT FRONT VERTICAL MOTOR CIRCUIT BREAKER OPERATION Connect the positive (+) lead and the negative (−) lead from the battery to the front vertical motor connector (illustrated terminals), and move the front edge of seat cushion to the highest position. Continue to apply voltage, and check that there is a circuit breaker operation noise within 4 to 60 seconds. (c) Reverse the polarity, and check that the seat cushion begins to descend within approximately 60 seconds. If operation is not as specified, replace the motor. 7. (a) INSPECT REAR VERTICAL MOTOR OPERATION Connect the positive (+) lead from the battery to terminal 2 and the negative (−) lead to terminal 1, and check that the motor turns clockwise. (b) Reverse the polarity, and check that the motor turns counterclockwise. If operation is not as specified, replace the motor. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BE−65 BODY ELECTRICAL 8. (a) (b) − POWER SEAT CONTROL SYSTEM INSPECT REAR VERTICAL MOTOR CIRCUIT BREAKER OPERATION Connect the positive (+) lead and the negative (−) lead from the battery to the rear vertical motor connector (illustrated terminals), and move the front edge of seat cushion to the highest position. Continue to apply voltage, and check that there is a circuit breaker operation noise within 4 to 60 seconds. (c) Reverse the polarity, check that the seat cushion begins to descend within approximately 60 seconds. If operation is not as specified, replace the motor. 9. INSPECT RECLINING MOTOR (DRIVER’S SIDE) OPERATION (a) Connect the positive (+) lead from the battery to terminal 1 and the negative (−) lead to terminal 2, and check that the motor turns clockwise. (b) Reverse the polarity, and check that the motor turns counterclockwise. If operation is not as specified, replace the motor. 10. (a) INSPECT RECLINING MOTOR (DRIVER’S SIDE) CIRCUIT BREAKER OPERATION Connect the positive (+) lead from terminal 1 and negative (−) lead to terminal 2. Check that the seat back reclines to the most forward position. (b) Continue to apply voltage, and check that there is a circuit breaker operation noise within 4 to 40 seconds. (c) Reverse the polarity, and check that the seat back starts to fall backwards within approximately 60 seconds. If operation is not as specified, replace the motor. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BE−66 BODY ELECTRICAL − POWER SEAT CONTROL SYSTEM 11. INSPECT RECLINING MOTOR (PASSENGER’S SIDE) OPERATION (a) Connect the positive (+) lead from the battery to terminal 1 and the negative (−) lead to terminal 2, and check that the motor turns counterclockwise. (b) Reverse the polarity, and check that the motor turns clockwise. If operation is not as specified, replace the motor. 12. (a) (b) INSPECT RECLINING MOTOR (PASSENGER’S SIDE) CIRCUIT BREAKER OPERATION Connect the positive (+) lead from the battery to terminal 2 and the negative (−) lead to terminal 1 on the seat wire harness side connector, and recline the seat back to the most forward position. Continue to apply voltage, and check that there is a circuit breaker operation noise within 4 to 40 seconds. (c) Reverse the polarity, and check that the seat back starts to fall backwards within approximately 60 seconds. If operation is not as specified, replace the motor. 13. (a) INSPECT LUMBAR SUPPORT MOTOR OPERATION Connect the positive (+) lead from the battery to terminal 1 and the negative (−) lead to terminal 2, and check that the lumber support moves release side. (b) Reverse the polarity, and check that the lumbar support moves forward. If operation is not as specified, replace the motor. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BE−67 BODY ELECTRICAL 14. (a) (b) − POWER SEAT CONTROL SYSTEM INSPECT LUMBAR SUPPORT MOTOR CIRCUIT BREAKER OPERATION Connect the positive (+) lead from the battery to terminal 2 and the negative (−) lead to terminal 1 on the lumbar support motor connector and move the lumbar support to front end position. Continue to apply voltage, and check that there is a circuit breaker operation noise within 4 to 60 seconds. (c) Reverse the polarity, and check that the lumbar support begins to move release side within approximately 60 seconds. If operation is not as specified, replace the motor. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BE−68 BODY ELECTRICAL − POWER MIRROR CONTROL SYSTEM POWER MIRROR CONTROL SYSTEM BE1MM−01 LOCATION 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 1206 Brought to you by BirfMark BE−69 BODY ELECTRICAL − POWER MIRROR CONTROL SYSTEM BE1MN−01 INSPECTION 1. OFF LEFT SIDE RIGHT SIDE UP LEFT OFF 2. RIGHT SIDE DOWN Z06854 3. Left side: INSPECT MIRROR SWITCH CONTINUITY Switch position Tester connection Specified condition OFF − UP 1 − 10, 3 − 4 Continuity DOWN 1 − 3, 4 − 10 Continuity LEFT 1 − 9, 3 − 4 Continuity RIGHT 1 − 3, 4 − 9 Continuity No continuity Off: INSPECT MIRROR SWITCH CONTINUITY Switch position Tester connection Specified condition OFF − UP 3−4 Continuity DOWN 1−3 Continuity LEFT 3−4 Continuity RIGHT 1−3 Continuity No continuity Right side: INSPECT MIRROR SWITCH CONTINUITY Switch position Tester connection Specified condition OFF − UP 1 − 6, 3 − 4 Continuity DOWN 1 − 3, 4 − 6 Continuity LEFT 1 − 2, 3 − 4 Continuity RIGHT 1 − 3, 2 − 4 Continuity No continuity If continuity is not as specified, replace the switch. 4. INSPECT MIRROR MOTOR OPERATION Connect the positive (+) lead from the battery to terminal in column ”A” and the negative (−) lead to terminal in column ”B”, check that the mirror operates in column ”C”. Switch position Tester connection Specified condition A (+) B (−) C (Operation) 2 3 Mirror turns upward 3 2 Mirror turns downward 1 3 Mirror turns to left side 3 1 Mirror turns to right side If operation is not as specified, replace the mirror assembly. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BE−70 BODY ELECTRICAL − AUDIO SYSTEM AUDIO SYSTEM BE0SA−01 DESCRIPTION 1. RADIO WAVE BAND The radio wave bands used in radio broadcasting are as follows: Frequency 30 kHz Designation 300 kHz LF 3 MHz MF HF AM Radio wave Modulation 30 MHz 300 MHz VHF FM Amplitube modulation Frequency modulation LF: Low Frequency MF: Medium Frequency HF: High Frequency VHF: Very High Frequency 2. SERVICE AREA There are great differences in the size of the service area for AM and FM monaural. Sometimes FM stereo broadcasts cannot be received even through AM can be received in very clearly. Not only does FM stereo have the smallest service area, but it also picks up static and other types of interference (”noise”) easily. FM (Stereo) FM (Monaural) AM BE2818 3. RECEPTION PROBLEMS Besides the problem of static, there are also the problems called ”fading”, ”multipath” and ”fade out”. These problems are caused not by electrical noise but by the nature of the radio waves themselves. Fading (1) lonosphere Fading Besides electrical interference, AM broadcasts are also susceptible to other types of interference, especially at night. This is because AM radio waves bounce off the ionosphere at night. These radio waves then interfere with the signals from the same transmitter that reach the vehicle’s antenna directly. This type of interference is called ”fading”. BE2819 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 1208 Brought to you by BirfMark BE−71 BODY ELECTRICAL Multipath − AUDIO SYSTEM (2) Multipath One type of interference caused by the bounce of radio waves off of obstructions is called ”multipath”. Multipath occurs when a signal from the broadcast transmitter antenna bounces off buildings and mountains and interferes with the signal that is received directly. (3) Fade Out Because FM radio waves are of higher frequencies than AM radio waves, they bounce off buildings, mountains, and other obstructions. For this reason, FM signals often seem to gradually disappear or fade away as the vehicle goes behind a building or other obstruction. This is called ”fade out”. BE2820 Fade Out BE2821 4. COMPACT DISC PLAYER Compact Disc (hereafter called ”CD”) Players use a laser beam pick−up to read the digital signals recorded on the CD and reproduce analog signals of the music, etc. There are 4.7 in. (12 cm) and 3.2 in. (8 cm) discs in the CD player. HINT: Never attempt to disassemble or oil any part of the player unit. Do not insert any object other than a disc into the magazine. NOTICE: CD players use an invisible laser beam which could cause hazardous radiation exposure. Be sure to operate the player correctly as instructed. 5. Example : Head Capstan (a) (b) Pinch Roller Tape Player/Head Cleaning: MAINTENANCE Raise the cassette door with your finger. Next, using a pencil or similar object, push in the guide. Using a cleaning pen or cotton applicator soaked in cleaner, clean the head surface, pinch rollers and capstans. N17398 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 1209 Brought to you by BirfMark BE−72 BODY ELECTRICAL − AUDIO SYSTEM 6. CD Player/Disc Cleaning: MAINTENANCE If the disc gets dirty, clean the disc by wiping the surface from the center to outside in the radial directions with a soft cloth. NOTICE: Do not use a conventional record cleaner or anti−static preservative. BE4331 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 1210 Brought to you by BirfMark BE−73 BODY ELECTRICAL − AUDIO SYSTEM BE1MR−01 TROUBLESHOOTING NOTICE: When replacing the internal mechanism (computer part) of the audio system, be careful that no part of your body or clothes comes in contact with the terminals of the leads from the IC, etc. of the replacement part (spare part). HINT: This inspection procedure is a simple troubleshooting which should be carried out on the vehicle during system operation and is based on the assumption that the cause of trouble lies with the system components (except for the wires and connectors, etc.). Always inspect the trouble taking the following items into consideration. S Open or short circuit of the wire harness S Connector or terminal connection fault Problem Radio Tape Player CD Player Antenna Noise No. No power coming in. 1 Power coming in, but radio not operating. 2 Noise present, but AM − FM not operating. 3 Either speaker does not work. 4 Either AM or FM does not work. 5 Reception poor (Volume faint). 5 Few preset tuning bands. 5 Sound quality poor. 6 Cannot set station select button. 7 Preset memory disappears. 7 Cassette tape cannot be inserted. 8 Cassette tape inserts, but no power. 9 Power coming in, but tape player not operating. 10 Either speaker does not work. 11 Sound quality poor (Volume faint). 12 Tape jammed, malfunction with tape speed or auto − reverse. 13 APS, SKIP, RPT buttons not operating. 14 Cassette tape will not eject. 15 CD cannot be inserted. 16 CD inserts, but no power. 17 Power coming in, but CD player not operating. 18 Sound jumps. 19 Sound quality poor (Volume faint). 20 Either speaker does not work. 21 CD will not eject. 22 Antenna does not fully extend of fully retract. 23 Antenna − related. 24 Noise produced by vibration or shock while driving. 25 Noise produced when engine starts. 26 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BE−74 BODY ELECTRICAL − AUDIO SYSTEM 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BE−75 BODY ELECTRICAL − AUDIO SYSTEM 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BE−76 BODY ELECTRICAL − AUDIO SYSTEM 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BE−77 BODY ELECTRICAL − AUDIO SYSTEM 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BE−78 BODY ELECTRICAL − AUDIO SYSTEM (See page BE−70) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BE−79 BODY ELECTRICAL − AUDIO SYSTEM 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BE−80 BODY ELECTRICAL − AUDIO SYSTEM 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BE−81 BODY ELECTRICAL − AUDIO SYSTEM 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BE−82 BODY ELECTRICAL − AUDIO SYSTEM 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BE−83 BODY ELECTRICAL − AUDIO SYSTEM (See page BE−70) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BE−84 BODY ELECTRICAL − AUDIO SYSTEM (See page BE−70) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BE−85 BODY ELECTRICAL − AUDIO SYSTEM 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BE−86 BODY ELECTRICAL − AUDIO SYSTEM 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BE−87 BODY ELECTRICAL − AUDIO SYSTEM 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BE−88 BODY ELECTRICAL − AUDIO SYSTEM 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BE−89 BODY ELECTRICAL − AUDIO SYSTEM 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BE−90 BODY ELECTRICAL − AUDIO SYSTEM 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BE−91 BODY ELECTRICAL − AUDIO SYSTEM 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BE−92 BODY ELECTRICAL − AUDIO SYSTEM 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BE−93 BODY ELECTRICAL − AUDIO SYSTEM BE1MQ−01 LOCATION 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BE−94 BODY ELECTRICAL − ANTENNA ANTENNA BE1MS−01 INSPECTION 1. w/ MOTOR ANTENNA: INSPECT ANTENNA SWITCH Except RADIO−LINKED TYPE Condition Tester connection Specified condition UP Button Position Free 2−5 Continuity UP Button Position Pushed in 4−5 Continuity DOWN Button Position Free 2−3 Continuity DOWN Button Position Pushed in 3−4 Continuity Illumination circuit 1−6 Continuity If continuity is not as specified, replace the switch. 2. (a) INSPECT ANTENNA MOTOR OPERATION Connect the positive (+) lead from the battery to terminal 1 and the negative (−) lead to terminal 2, and check that the motor turns (moves upward.) (b) Then, reverse the polarity, check that the motor turns the opposite way (moves downward.) If operation is not as specified, replace the motor. 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 1232 Brought to you by BirfMark BE−95 BODY ELECTRICAL − CLOCK CLOCK BE1MT−01 TROUBLESHOOTING HINT: Troubleshoot the lock according to the table below. Clock will not operate 1 Clock loses or gains time 2 1.5 seconds/day 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 1233 Brought to you by BirfMark BE−96 BODY ELECTRICAL − CLOCK 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 1234 Brought to you by BirfMark BO−1 BODY − CLIP CLIP BO37F−01 REPLACEMENT The removal and installation methods of typical clips used in body parts are shown in the table below. HINT: If the clip is damaged during the operation, always replace it with a new clip. Pliers Clip Remover Screwdriver Scraper V00005 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 1235 Brought to you by BirfMark BO−2 BODY Shape (Example) − CLIP Removal / Installation Installation Removal Removal Installation V00012 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 1236 Brought to you by BirfMark BO−3 BODY − SRS AIRBAG SRS AIRBAG BO37G−01 PRECAUTION The LAND CRUISER is equipped with an SRS (Supplemental Restraint System) such as the driver airbag and front passenger airbag. Failure to carry out service operation in the correct sequence could cause the SRS to unexpectedly deploy during servicing, possibly leading to a serious accident. Before servicing (including removal or installation of parts, inspection or replacement), be sure to read the precautionary notices in the RS section. 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 1237 Brought to you by BirfMark BO−4 BODY − FRONT BUMPER FRONT BUMPER BO37H−01 COMPONENTS CAUTION: The side rail extensions are necessary for normal functioning of the SRS airbag, so make sure that they are correctly installed.When replacing the bumper, always inspect the side rail extensions. If they are deformed or cracked, replace them. Torque: 39 N·m (400 kgf·cm, 29 ft·lbf) 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 1238 Brought to you by BirfMark BO−5 BODY − REAR BUMPER REAR BUMPER BO37I−01 COMPONENTS 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 1239 Brought to you by BirfMark BO−6 BODY − HOOD HOOD Centering Bolt Bolt with Washer BO37J−01 ADJUSTMENT HINT: Since the centering bolt is used as the hood hinge and lock set bolt, the hood and lock cannot be adjusted with it on. Substitute the bolt with washer for the centering bolt. BO5235 1. ADJUST HOOD IN FORWARD/REARWARD AND LEFT /RIGHT DIRECTIONS Adjust the hood by loosening the hood side hinge bolts. Torque: 18 N·m (185 kgf·cm, 13 ft·lbf) 2. (a) (b) ADJUST FRONT EDGE OF HOOD IN VERTICAL DIRECTIONS Loosen the lock nut. Adjust the hood by turning the cushions. 3. ADJUST REAR EDGE OF HOOD IN VERTICAL DIRECTIONS Adjust the hood by loosening the body side hinge bolts. 4. ADJUST HOOD LOCK Adjust the hood lock by loosening the mounting bolts. Torque: 8.0 N·m (80 kgf·cm, 69 in.·lbf) 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 1240 Brought to you by BirfMark BO−7 BODY − HOOD SUPPORT BO37K−01 REPLACEMENT 1. REMOVE DAMPER STAY FROM HOOD Remove the 2 bolts and support from the hood. HINT: While supporting the hood with your hand, remove the hood. 2. REMOVE DAMPER STAY FROM BODY Remove the 2 bolts and support. 3. REPLACE DAMPER STAY NOTICE: S Do not disassemble the damper stay because the cylinder is filled with pressurized gas. If the damper stay is to be replaced, drill a 2.0 − 3.0 mm (0.079 − 0.118 in.) hole as shown in the illustration to completely release the high−pressure gas before disposing of it. S When drilling, chips may fly out so work carefully. S The gas is colorless, odorless and non−toxic. S When working, handle the damper stay carefully. Never score or scratch the exposed part of the piston rod, and never allow paint or oil to get on it. S Do not turn the piston rod and cylinder with the damper stay fully extended. 4. INSTALL DAMPER STAY Install the damper stay. S Hole Here Cylinder Piston Rod 10 − 20 mm (0.39 − 0.99 in.) BO5366 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 1241 Brought to you by BirfMark BO−8 BODY − FRONT DOOR FRONT DOOR BO37L−01 COMPONENTS 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 1242 Brought to you by BirfMark BO−9 BODY − FRONT DOOR DISASSEMBLY BO37N−01 HINT: Tape a screwdriver tip before using to pry parts. 1. REMOVE DOOR INSIDE HANDLE BEZEL 2. 3. 4. 5. REMOVE ARMREST REMOVE ARMREST PANEL BASE UPPER REMOVE COURTESY LIGHT REMOVE LOWER FRAME BRACKET GARNISH 6. (a) (b) REMOVE DOOR TRIM Remove the 3 screws from the door trim. Using a screwdriver, remove the clip and remove the trim by pulling all of the trim up. Remove the 11 screws and armrest base from the door trim. Remove the inner weatherstrip from the door trim. Remove the 8 screws and door pocket from the door trim. (c) (d) (e) 7. REMOVE DOOR BELT MOULDING Pry out the clip from the edge of the panel, and remove the moulding . 8. REMOVE DOOR WEATHERSTRIP NOTICE: Do not pull strongly on the weatherstrip as it may tear. 9. REMOVE DOOR INSIDE HANDLE 10. REMOVE DOOR LOCK CONTROL RELAY 11. REMOVE SERVICE HOLE COVER Cotton Tape NOTICE: Do not block the trim clip sealing with the tape. 12. REMOVE OUTSIDE REAR VIEW MIRROR 13. REMOVE DOOR GLASS RUN 14. REMOVE REAR LOWER FRAME Panel Cover BO2455 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BO−10 BODY − FRONT DOOR HINT: At the time of reassembly, adjust the equalizer arm up to down and tighten if where dimensions A and B, as shown are equal. 15. 16. REMOVE DOOR GLASS REMOVE WINDOW REGULATOR Torque: 5.0 N·m (50 kgf·cm, 43 in.·lbf) HINT: At the time of reassembly, apply MP grease to the sliding surface and gears of the window regulator. NOTICE: Do not apply grease to the spring. 17. REMOVE LOCKING AND OPENING CONTROL LINK 18. REMOVE DOOR LOCK HINT: At the time of reassembly, apply adhesive to the 3 screws. Part No.08833−00070, THREE BOND 1324 or equivalent Torque: 5.0 N·m (50 kgf·cm, 43 in.·lbf) HINT: At the time of reassembly, apply MP grease to the sliding surface of the door lock. 19. REMOVE DOOR OUTSIDE HANDLE 20. REMOVE DOOR LOCK CYLINDER 21. REMOVE DOOR SPEAKER 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BO−11 BODY − FRONT DOOR REPLACEMENT 1. 2. 3. BO37O−01 REMOVE GLASS CHANNEL WITH SCREWDRIVER OR LIKE OBJECT APPLY SOAPY WATER TO INSIDE OF WEATHERSTRIP INSTALL CHANNEL BY TAPPING IT WITH PLASTIC HAMMER 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BO−12 BODY − FRONT DOOR ADJUSTMENT BO37M−01 1. ADJUST DOOR IN FORWARD/REARWARD AND VERTICAL DIRECTIONS Using SST, adjust the door by loosening the body side hinge bolts. SST 09812−00010 Torque: 24 N·m (240 kgf·cm, 17 ft·lbf) 2. ADJUST DOOR IN LEFT/RIGHT AND VERTICAL DIRECTIONS Loosen the door side hinge bolts to adjust. Torque: 24 N·m (240 kgf·cm, 17 ft·lbf) 3. (a) (b) (c) ADJUST DOOR LOCK STRIKER Check that the door fit and door lock linkages are adjusted correctly. Loosen the striker mounting screws to adjust. Using a plastic hammer, tap the striker to adjust it. BO2556 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BO−13 BODY − FRONT DOOR BO37P−01 REASSEMBLY Reassembly is in the reverse order of disassembly (See page BO−9.) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BO−14 BODY − REAR DOOR REAR DOOR BO37Q−01 COMPONENTS 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 1248 Brought to you by BirfMark BO−15 BODY − REAR DOOR DISASSEMBLY BO37S−01 HINT: Tape a screwdriver tip before using to pry parts. 1. REMOVE DOOR INSIDE HANDLE BEZEL 2. REMOVE DOOR SPEAKER COVER 3. 4. 5. REMOVE ASH TRAY REMOVE ARMREST BASE UPPER REMOVE ARMREST 6. (a) (b) (c) REMOVE DOOR TRIM Remove the courtesy light. Remove the 3 screws from the door trim. Using a screwdriver, remove the clips and remove the trim by pulling all of the trim up. Remove the inner weatherstrip from the door trim. Remove the 11 screws and the armrest base from the door trim. (d) (e) 7. REMOVE DOOR BELT MOULDING Pry out the clip from the edge of the panel, and remove the moulding. 8. REMOVE DOOR WEATHERSTRIP NOTICE: Do not pull strongly on the weatherstrip as it may tear. 9. REMOVE DOOR INSIDE HANDLE 10. REMOVE SERVICE HOLE COVER 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BO−16 BODY Cotton Tape Panel Cover BO2455 − REAR DOOR NOTICE: Do not block the clip sealing with the tape. 11. REMOVE DOOR SPEAKER 12. REMOVE LINK PROTECTOR 13. REMOVE LOCKING LINK AND DOOR OPENING LINK 14. REMOVE DOOR GLASS RUN 15. REMOVE REAR LOWER FRAME 16. REMOVE QUARTER WINDOW GLASS WITH WEATHERSTRIP 17. REMOVE DOOR GLASS 18. REMOVE WINDOW REGULATOR Torque: 5.0 N·m (50 kgf·cm, 43 in.·lbf) HINT: At the time of reassembly, apply MP grease to the sliding surface and gears of the regulator. NOTICE: Do not apply grease to the spring. 19. REMOVE DOOR LOCK HINT: At the time of reassembly, apply adhesive to the 3 screws. Part No.08833−00070, THREE BOND 1324 or equivalent Torque: 5.0 N·m (50 kgf·cm, 43 in.·lbf) HINT: At the time of reassembly, apply MP grease to the sliding surface of the door lock. 20. REMOVE OUTSIDE HANDLE 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BO−17 BODY − REAR DOOR REPLACEMENT 1. 2. 3. BO37T−01 REMOVE GLASS CHANNEL WITH SCREWDRIVER OR LIKE OBJECT APPLY SOAPY WATER TO INSIDE OF WEATHERSTRIP INSTALL CHANNEL BY TAPPING IT WITH PLASTIC HAMMER 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BO−18 BODY − REAR DOOR ADJUSTMENT BO37R−01 1. ADJUST DOOR IN FORWARD/REARWARD AND VERTICAL DIRECTIONS Adjust the door by loosening the body side hinge bolts. Torque: 24 N·m (240 kgf·cm, 17 ft·lbf) 2. ADJUST DOOR IN LEFT /RIGHT AND VERTICAL DIRECTIONS Adjust the door by loosening the door side hinge bolts. Torque: 24 N·m (240 kgf·cm, 17 ft·lbf) 3. (a) (b) (c) ADJUST DOOR LOCK STRIKER Check that the door fit and door lock linkages are adjusted correctly. Loosen the striker mounting screws to adjust. Using a plastic hammer, tap the striker to adjust it. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BO−19 BODY − REAR DOOR BO37U−01 REASSEMBLY Reassembly is in the reverse order of disassembly (See page BO−15). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BO−20 BODY − BACK DOOR BACK DOOR BO37V−01 COMPONENTS 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 1254 Brought to you by BirfMark BO−21 BODY − BACK DOOR DISASSEMBLY BO37W−01 HINT: Tape the screwdriver tip before using to pry parts. 1. REMOVE UPPER BACK DOOR (a) Remove the pull handle and pull handle bezel. (b) Remove the back door trim. (1) Insert a screwdriver, between the retainers and trim to pry it loose. (2) Remove the back door trim. (c) Remove the door weatherstrip. NOTICE: Do not pull strongly on the weatherstrip as it may tear. (d) Remove the weatherstrip upper. NOTICE: Do not pull strongly off the weatherstrip as it may tear. (e) Remove the door inside handle. (f) (g) (h) (i) Remove Remove Remove Remove the door lock control. the outside handle. the door lock cylinder. the wiper arm. (j) (k) (l) (m) Remove Remove Remove Remove the the the the 2. (a) REMOVE LOWER BACK DOOR Remove the door trim. (1) Insert a screwdriver, between the retainers and door trim to pry it loose. (2) Remove the door trim. wiper motor. wiper control relay. door lock. damper stay. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BO−22 BODY (b) (c) (d) (e) Panel − BACK DOOR Remove Remove Remove Remove the service hole cover. the door lock control. the door lock. the license plate light cover. Cotton Tape Cover BO2455 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BO−23 BODY − BACK DOOR ADJUSTMENT BO37X−01 1. (a) ADJUST UPPER BACK DOOR Adjust the door in forward/rearward and left/right directions. Adjust the door by loosening the door side hinge bolts. (b) Adjust the door in left/right and vertical directions. Adjust the door by loosening the body side hinge bolts. (c) Adjust the door lock striker. (1) Check that the door fit and door lock linkage are adjusted correctly. (2) Adjust the striker position by slightly loosening the striker mounting screws, and hitting the striker with a hammer. Tighten the striker mounting screw again. 2. (a) ADJUST LOWER BACK DOOR Adjust the door in forward/rearward and left/right directions. Adjust the door by loosening the door side hinge bolts. (b) Adjust the door in left/right and vertical directions. Adjust the door by loosening the body side hinge bolts. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BO−24 BODY (c) − BACK DOOR Adjust the door lock striker. (1) Check that the door fit and door lock linkages are adjusted correctly. (2) Adjust the striker position by slightly loosening the striker mounting screws, and hitting the striker with a hammer. (3) Tighten the striker mounting screws again. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BO−25 BODY − BACK DOOR BO37Y−01 REASSEMBLY Reassembly is in the reverse order of disassembly(See page BO−21). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BO−26 BODY − BACK DOOR STAY BACK DOOR STAY BO37Z−01 REPLACEMENT 1. REMOVE DAMPER STAY FROM BACK DOOR Remove the 2 bolts and support from the hood. HINT: While supporting the hood with your hand, remove the hood. 2. REMOVE DAMPER STAY FROM BODY Remove the 2 bolts and support. Hole Here Cylinder Piston Rod 10 − 20 mm (0.39 − 0.99 in.) BO5366 3. REPLACE DAMPER STAY NOTICE: S Do not disassemble the damper stay because the cylinder is filled with pressurized gas. S If the damper stay is to be replaced, drill a 2.0 − 3.0 mm (0.079 − 0.118 in.) hole in the aved shown in the illustration to completely release the high−pressure gas before disposing of it. S When drilling, chips may fly out so work carefully. S The gas is colorless, odorless and non−toxic. S When working, handle the damper stay carefully. Never score or scratch the exposed part of the piston rod, and never allow paint or oil to get on it. S Do not turn the piston rod and cylinder with the damper stay fully extended. 4. INSTALL DAMPER STAY Install the damper stay. 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 1260 Brought to you by BirfMark BO−27 BODY − FRONT WIPER AND WASHER FRONT WIPER AND WASHER BO380−01 COMPONENTS 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 1261 Brought to you by BirfMark BO−28 BODY − FRONT WIPER AND WASHER REMOVAL BO382−01 1. 2. REMOVE WIPER ARMS REMOVE COWL LOUVER 3. (a) REMOVE WIPER MOTOR AND WIPER LINK Disconnect the connector, then unfasten 4 bolts and wiper motor. Remove the wiper link. (b) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BO−29 BODY − FRONT WIPER AND WASHER BO48K−01 INSPECTION 1. (a) INSPECT FRONT WASHER NOZZLE While operating the washer, check that both the point where the washer fluid from the upper nozzles hits the windshield, and the upsurge area, are within the range indicated by the arrow. A (b) Approx. 460 mm (18.1 in.) B Approx. 300 mm (11.8 in.) C Approx. 250 mm (9.84 in.) D Approx. 400 mm (15.7 in.) E Approx. 410 mm (16.1 in.) F Approx. 220 mm (8.66 in.) G Approx. 60 mm (2.36 in.) Check if the lower point where the washer fluid hits the windshield is within the range of the wiping pattern (the area of the glass which is wiped by the wiper blades). 2. ADJUST FRONT WASHER NOZZLE Using a tool like that shown in the illustration, change the direction of the nozzle hole to adjust the point where washer fluid strikes the windshield. 2 − 2.5 mm (0.079 − 0.098 in.) 0.7 − 0.75 mm (0.028 − 0.030 in.) BE3367 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BO−30 BODY − FRONT WIPER AND WASHER INSTALLATION 1. 2. 3. 4. (a) (b) (c) BO383−01 INSTALL WIPER LINK Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf) INSTALL WIPER MOTOR Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf) INSTALL COWL LOUVER INSTALL FRONT WIPER ARM Install the wiper arms and operate the wipers once and turn the wiper switch OFF. Adjust the installation positions of the wiper arms to the positions as shown in the illustration. A: Approx. 25 mm (0.98 in.) Tighten the nuts. Torque: 20 N·m (210 kgf·cm, 15 ft·lbf) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BO−31 BODY − REAR WIPER AND WASHER REAR WIPER AND WASHER REMOVAL BO385−01 1. REMOVE PULL HANDLE AND PULL HANDLE BEZEL 2. (a) REMOVE BACK DOOR TRIM Insert a screwdriver between the retainers and door trim to pry it loose. HINT: Tape the screwdriver tip before use. (b) Remove the back door trim. 3. (a) (b) (c) (d) 4. REMOVE WIPER ARM, MOTOR AND REAR WIPER CONTROL RELAY Open the cap. Remove the nut and wiper arm. Remove the 5 bolts and motor, then disconnect the connector. Remove the bolts and rear wiper control relay,then disconnect the connector. ADJUST REAR WASHER NOZZLE 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 1265 Brought to you by BirfMark BO−32 BODY − REAR WIPER AND WASHER BO386−01 INSPECTION INSPECT REAR WASHER NOZZLE While operating the washer, check whether the point where the washer fluid hits the back door glass and the upsurge area are within the range indicated by the hatched line. A Approx. 120 mm (4.72 in.) B Approx. 120 mm (4.72 in.) C Approx. 90 mm (3.54 in.) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BO−33 BODY − REAR WIPER AND WASHER INSTALLATION 1. 2. 3. 4. 5. 6. (a) (b) (c) BO387−01 INSTALL WIPER CONTROL RELAY INSTALL WIPER MOTOR Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf) INSTALL BACK DOOR TRIM INSTALL PULL HANDLE BEZEL INSTALL PULL HANDLE INSTALL REAR WIPER ARM Install the wiper arm and operate the wipers once and turn the wiper switch OFF. Adjust the installation positions of the wiper arm to the positions shown in the illustration. A: Approx. 40 mm (1.57 in.) Tighten the nut. Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BO−34 BODY − BODY OUTSIDE MOULDING BODY OUTSIDE MOULDING BO48L−01 COMPONENTS 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 1268 Brought to you by BirfMark BO−35 BODY − BODY OUTSIDE MOULDING REMOVAL BO48M−01 1. REMOVE ROOF DRIP MOULDING Using SST, pull off the roof drip moulding from front ends. SST 09806−30010 2. REMOVE FRONT DOOR BELT MOULDING (See page BO−9) 3. REMOVE REAR DOOR BELT MOULDING (See page BO−15) 4. REMOVE QUARTER BELT MOULDING Pry out the clips from the edge of the panel, and remove the moulding. BO5153 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BO−36 BODY − BODY OUTSIDE MOULDING INSTALLATION BO48N−01 1. INSTALL ROOF DRIP MOULDING Attach the upper edge of the moulding to the body flange. Tap on the moulding by hand. 2. INSTALL FRONT DOOR BELT MOULDING 3. INSTALL REAR DOOR BELT MOULDING 4. INSTALL QUARTER BELT MOULDING 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BO−37 BODY − WHEEL OPENING MOULDING WHEEL OPENING MOULDING BO48O−01 COMPONENTS Quarter Outside Moulding Front Fender Wheel Moulding 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 1271 Brought to you by BirfMark BO−38 BODY − WHEEL OPENING MOULDING REMOVAL 1. BO48P−01 (a) (b) (c) (d) (e) (f) REMOVE FRONT FENDER WHEEL OPENING MOULDING Remove the charcoal canister. Remove the air cleaner case assembly. Remove the cool air intake duct. Remove the front wheel. Remove the front mudguard. Remove the front bumper extension. (g) Remove the 4 nuts from engine room inside service hole. (h) (i) Remove the 2 screws. Remove the front wheel opening extension. 2. REAR DOOR SIDE: REMOVE REAR WHEEL OPENING MOULDING Remove the 2 bolts and moulding. N14081 3. (a) REMOVE REAR WHEEL OPENING MOULDING Remove the mud guard, bumper extention and back door scuff plate. N14075 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BO−39 BODY − WHEEL OPENING MOULDING (b) Remove the quarter trim RH. (c) Remove the quarter trim LH. 4. (a) REMOVE QUARTER OUTSIDE MOULDING Remove the 2 nuts. (b) Remove the screw. (c) Using a screwdriver, pry out the rearwheel moulding. N14076 N14077 N14078 N14079 N14440 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BO−40 BODY − WHEEL OPENING MOULDING INSTALLATION BO48Q−01 1. (a) INSTALL FRONT WHEEL OPENING MOULDING Install the front wheel opening moulding. (b) Install the 4 nuts from the service hole of the engine room inside. Install the 2 screws. Front bumper extension Front mudguard Front wheel Cool air intake duct Air cleaner case assembly Charcoal canister (c) (d) (e) (f) (g) (h) (i) 2. INSTALL QUARTER OUTSIDE MOULDING Install the quarter outside moulding with the 2 bolts. 3. (a) (b) (c) (d) (e) (f) (g) INSTALL REAR WHEEL OPENING MOULDING Install the rear wheel opening moulding with the 2 nuts. Install the screw. Install the quarter trim LH. Install the quarter trim RH. Install the back door scuff plate. Install the rear bumper extension. Install the rear mudguard. N14082 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BO−41 BODY − SIDE PROTECTION MOULDING SIDE PROTECTION MOULDING BO38H−01 COMPONENTS 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 1275 Brought to you by BirfMark BO−42 BODY − SIDE PROTECTION MOULDING REMOVAL BO38I−01 1. REMOVE ENDS OF MOULDING Using a scraper, pry the moulding loose about 30 mm (1.18 in.) from the ends. HINT: Tape the scraper tip before use. 2. (a) (b) REMOVE MOULDING AND ADHESIVE Pull off the moulding by cutting the adhesive with a knife. Scrape off adhesive from the body with a cutter or sandpaper. NOTICE: Remember that 30−80 mm (1.18−3.15 in.) of the ends of the moulding are glued tightly with a strong adhesive.Do not reuse moulding. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BO−43 BODY − SIDE PROTECTION MOULDING INSTALLATION BO38J−01 HINT: Precautions for storing moulding materials: S Store in cool place, avoiding direct sunlight, high temperature and dust. S The moulding is of polyvinyl chloride, so do not allow it to come in contact with thinner or other solvent, open flame, or boiling water. S The storage time for the moulding and adhesive are limited to about 9 months. 1. CLEAN MOULDING MOUNTING SURFACE Wipe off stains with cleaner. 2. HEAT BODY MOUNTING SURFACE Using a heat light, heat the body mounting surface to 30−50 °C (86−122 °F). NOTICE: When the moulding is installed, the temperature of the mounting surface should be 20 °C (68 °F) or higher. BO6675 3. (a) HEAT MOULDING Using a heat light, heat the moulding to 30−60 °C (86−140 °F). NOTICE: Do not heat the moulding excessively. (b) The temperature should not be higher than 80 °C (176 °F). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BO−44 BODY − SIDE PROTECTION MOULDING 4. APPLY ADHESIVE TO MOULDING Apply adhesive to both punched out ends of the moulding. NOTICE: Install the moulding within 7 minutes after applying the adhesive. Part No. 08850−00051 5. LIFT MOULDING RELEASE SHEET FROM FACE OF MOULDING NOTICE: When the moulding release sheet is removed, be sure that no dirt or dust can get onto the uncovered area. BO5229 6. INSTALL MOULDING Push the moulding to the body, as shown in the illustration. NOTICE: S Be sure that the body and moulding are heated to the proper temperature. S Do not depress the adhesive−coated parts excessively but just hold them down with your thumb. S Scrape off any overflowing adhesive with a plastic spatula and clean the surface with a dry rag. S After installation, do not wash the vehicle for 24 hours. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BO−45 BODY − WINDSHIELD WINDSHIELD BO38P−01 COMPONENTS 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 1279 Brought to you by BirfMark BO−46 BODY − WINDSHIELD REMOVAL 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. BO38Q−01 REMOVE HOOD REMOVE WIPER ARMS REMOVE COWL LOUVER REMOVE INNER REAR VIEW MIRROR REMOVE PERSONAL LIGHT ASSEMBLY REMOVE PERSONAL LIGHT COVER REMOVE SUN VISORS AND HOLDERS REMOVE ASSIST GRIPS REMOVE FRONT PILLAR GARNISHES LOOSEN ROOF HEADLINING 11. REMOVE WINDSHIELD GLASS (a) From the outside of the vehicle , cut off the weatherstrip. NOTICE: Do not damage the body and the glass. (b) Push piano wire through between the body and glass from the interior. (c) Tie both wire ends to the wooden blocks or equivalent. NOTICE: When separating, take care not to damage the paint or interior ornaments. To prevent scratching the safety pad when removing the windshield, place a plastic sheet between the piano wire and safety pad. (d) (e) Cut the adhesive by pulling the piano wire around it. Remove the glass. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BO−47 BODY − WINDSHIELD INSTALLATION BO38R−01 1. CLEAN BODY AND GLASS Using a cleaner, clean the weatherstrip contacting surface of the body and the glass. BO4421 2. (a) INSTALL WEATHERSTRIP Apply primer to the weatherstrip on the contact surface with glass as shown in the illustration. PRIMER: Sunstar−9002 T or equivalent NOTICE: Let the primer coating dry for 3 minutes or more. (b) (c) (d) (e) Cut off the tip of the cartridge nozzle. Fill the cartridge with adhesive. Apply adhesive to the weatherstrip on the glass edge retaining surface as shown in the illustaration. ADHESIVE: Sikaflex−256 HV or equivalent Install the weatherstrip to the glass. Clean the weatherstrip. 3. (a) INSTALL GLASS Apply a working cord along the weatherstrip groove, as shown in the illustration. (b) Apply primer to the weatherstrip on the surface with body as shown in the illustration. PRIMER: Sunstar−9002 T or equivalent 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BO−48 BODY (c) (d) − WINDSHIELD Begin installation in the middle of the lower part of the glass. Hold the glass in position on the body. (e) From the inside, pull off one cord at an angle so it pulls the lip over the flange. From the outside, press the glass along the weatherstrip until the glass is installed. (f) To make the glass fit snugly, tap from the outside with your open hand. 4. (a) APPLY ADHESIVE Put masking tape around the weatherstrip to protect the paint and the glass. (b) Cut off the tip of the cartridge nozzle. Fill the cartridge with adhesive. Lift the lip of the weatherstrip (with hand) land and fill adhesive into the clearance. ADHESIVE: Sikaflex−256HV or equivalent CLEANING SEALER SURFACE Apply auto glass sealer dry, remove the masking tape. (c) 5. (a) HINT: The auto glass sealer will harden in about 15 hours. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BO−49 BODY (b) 6. (a) (b) 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. − WINDSHIELD Clean off the sealer oozing out from the masking tape with a clean rag saturated in cleaner. INSPECT FOR LEAKS AND REPAIR Do a leak test. Seal any leaks with auto glass sealer. Part No. 08833−00030 or equivalent INSTALL ROOF HEADLINING INSTALL FRONT PILLAR GARNISHES INSTALL ASSIST GRIPS INSTALL SUN VISORS AND HOLDERS INSTALL PERSONAL LIGHT COVER INSTALL PERSONAL LIGHT ASSEMBLY INSTALL INNER REAR VIEW MIRROR INSTALL COWL LOUVER INSTALL WIPER ARMS Torque: 20 N·m(205 kgf·cm, 15 ft·lbf) INSTALL HOOD Torque: 18 N·m(185 kgf·cm, 13 ft·lbf) ADJUST HOOD (See page BO−6) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BO−50 BODY − QUARTER WINDOW GLASS QUARTER WINDOW GLASS BO38S−01 COMPONENTS 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 1284 Brought to you by BirfMark BO−51 BODY − QUARTER WINDOW GLASS REMOVAL 1. BO38T−01 2. 3. w/ No. 2 rear seat: NO. 2 REAR SEAT REMOVE BACK DOOR SCUFF PLATE REMOVE QUARTER TRIM 4. 5. REMOVE REAR SEAT SIDE GARNISH REMOVE REAR DOOR SCUFF PLATE 6. 7. 8. 9. REMOVE QUARTER PILLAR GARNISH REMOVE REAR PILLAR GARNISH REMOVE ASSIST GRIPS LOOSEN ROOF HEADLINING 10. REMOVE VENT LOUVER AND QUARTER BELT MOULDING Remove the nut from the vent louver. (a) (b) Insert a screwdriver between the retainers and body to pry it loose. HINT: Tape the screwdriver tip before use. (c) Pull out the vent louver. (d) Pull out the clips from the edge of the panel, and remove the moulding. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BO−52 BODY − QUARTER WINDOW GLASS 11. If reusing the weatherstrip: REMOVE QUARTER WINDOW GLASS (a) Using a screwdriver loosen the weatherstrip from the body. NOTICE: Be careful not to damage the body. (b) Pry the lip of the weatherstrip outward from the interior part of the body flange. (c) Pull the glass outwards and remove it with the weatherstrip. 12. If using a new weatherstrip: REMOVE QUARTER WINDOW GLASS (a) From outside of the vehicle, cut off the weatherstrip lip with a knife. NOTICE: Do not damage the body and the glass. (b) Push the glass outwards and remove the glass. (c) Remove the remaining weatherstrip. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BO−53 BODY − QUARTER WINDOW GLASS DISASSEMBLY BO38U−01 1. Slide Type: REMOVE CENTER SASH Remove the screw and weatherstrip. 2. REMOVE QUARTER WINDOW GLASS Pull up the sash and remove the 2 glasses. 3. REMOVE QUARTER WINDOW GLASS RUN FROM SASH 4. REMOVE QUARTER WINDOW WEATHERSTRIP FROM SASH 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BO−54 BODY − QUARTER WINDOW GLASS REASSEMBLY 1. BO38V−01 Slide type: INSTALL QUARTER WINDOW WEATHERSTRIP ON SASH NOTICE: If the weatherstrip has hardened, it may develop leaks. HINT: Use a new one if possible. 2. INSTALL QUARTER WINDOW GLASS RUN 3. INSTALL QUARTER WINDOW GLASS Pull up on the sash and install 2 glasses. 4. INSTALL CENTER SASH Install the weatherstrip with the screw. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BO−55 BODY − QUARTER WINDOW GLASS INSTALLATION BO38W−01 1. INSTALL WEATHERSTRIP ON GLASS (a) Attach the weatherstrip to the glass. NOTICE: If the weatherstrip has hardened, it may develop leaks. Use a new one if possible. (b) Insert a cord into the groove of the weatherstrip all the way around with the ends overlapping. 2. (a) INSTALL QUARTER WINDOW GLASS Apply soapy water to contact surface of the weatherstrip lip and to the body flange. HINT: Begin installation in the middle of the lower part of the quarter window glass. (b) Hold the glass in position on the body. (c) From the inside, pull on one cord at an angle so it pulls the lip over the flange. From the outside, press the glass along the weatherstrip until the glass is installed. 3. FIX IN GLASS To make the glass fix snugly, tap from the outside with your open hand. 4. INSPECT FOR LEAKS AND REPAIR (a) Do a leak test. (b) Seal any leak with auto glass sealer. 5. INSTALL ROOF HEADLINING 6. INSTALL ASSIST GRIPS 7. INSTALL REAR PILLAR GARNISH 8. INSTALL QUARTER PILLAR GARNISH 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BO−56 BODY 9. 10. 11. 12. 13. − QUARTER WINDOW GLASS INSTALL REAR DOOR SCUFF PLATE INSTALL REAR SEAT SIDE GARNISH INSTALL QUARTER TRIM INSTALL BACK DOOR SCUFF PLATE w/ No. 2 Rear Seat: INSTALL NO. 2 REAR SEAT 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BO−57 BODY − BACK DOOR GLASS BACK DOOR GLASS BO38X−01 COMPONENTS 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 1291 Brought to you by BirfMark BO−58 BODY − BACK DOOR GLASS BO38Y−01 REMOVAL 1. REMOVE WIPER ARM 2. REMOVE DEFOGGER CONNECTOR Disconnect the connector from the glass. 3. REMOVE BACK DOOR GLASS HINT: Remove the glass in the same manner as the windshield. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BO−59 BODY − BACK DOOR GLASS BO38Z−01 INSTALLATION HINT: Install the glass and weatherstrip in the same manner as the windshield. 1. CLEAN BODY AND GLASS 2. INSTALL WEATHERSTRIP ON GLASS 3. INSTALL BACK DOOR GLASS 4. FIX IN GLASS 5. APPLY ADHESIVE Part No. 08833−00030 or equivalent 6. CLEAN SEALER SURFACE 7. INSPECT FOR LEAKS AND REPAIR Part No. 08833−00030 or equivalent 8. CONNECT DEFOGGER WIRE CONNECTORS Connect the connector to the glass. 9. CONNECT WIPER ARM Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BO−60 BODY − SLIDING ROOF SLIDING ROOF BO390−01 COMPONENTS 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 1294 Brought to you by BirfMark BO−61 BODY − SLIDING ROOF 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 1295 Brought to you by BirfMark BO−62 BODY − SLIDING ROOF 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 1296 Brought to you by BirfMark BO−63 BODY − SLIDING ROOF REMOVAL BO393−01 HINT: Tape the screwdriver tip before using to pry parts. 1. CHECK OPERATION TO THE SLIDING ROOF 2. 3. REMOVE BACK DOOR SCUFF PLATE w/ No. 2 Rear Seat REMOVE NO. 2 REAR SEAT 4. REMOVE QUARTER TRIM RH 5. REMOVE QUARTER TRIM LH 6. 7. 8. 9. 10. REMOVE REAR SEAT SIDE GARNISH REMOVE REAR DOOR SCUFF PLATE REMOVE COWL SIDE TRIM REMOVE FRONT AND REAR DOOR OPENING TRIM REMOVE CENTER PILLAR LOWER GARNISH 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BO−64 BODY 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. (a) (b) (c) − SLIDING ROOF REMOVE FRONT SEAT OUTER BELT SHOULDER ANCHOR REMOVE CENTER PILLAR UPPER GARNISH REMOVE FRONT SHOULDER BELT ANCHOR ADJUSTER REMOVE NO. 1 REAR SEAT OUTER BELT SHOULDER ANCHOR w/ No. 2 Rear Seat REMOVE NO. 2 REAR SEAT OUTER BELT SHOULDER ANCHOR REMOVE QUARTER AND REAR PILLAR GARNISH REMOVE ASSIST GRIPS REMOVE FRONT PILLAR GARNISH REMOVE SUN VISORS AND HOLDERS REMOVE INNER REAR VIEW MIRROR REMOVE PERSONAL LIGHT ASSEMBLY AND PERSONAL LIGHT COVER REMOVE NO. 1 AND NO. 2 ROOM LIGHT REMOVE BACK DOOR OPENING TRIM REMOVE SLIDING ROOF OPENING MOULDING (d) REMOVE CONTROL SWITCH Remove the screw. Using a screwdriver, remove the switch cover. Remove the 2 screws and switch body, then disconnect the connector. Remove the 2 screws and bracket. 26. (a) (b) REMOVE ROOF HEADLINING Using the clip remover, remove the 7 clips. Remove the roof headlining. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BO−65 BODY 27. (a) (b) (c) − SLIDING ROOF REMOVE DRIVE GEAR ASSEMBLY Remove the bolt and drive gear control relay, then disconnect the connector. Remove the 2 bolts and bracket. Remove the 4 bolts and drive gear assembly, then disconnect the connector. 28. REMOVE SLIDING ROOF GARNISHES Using a screwdriver, pry loose the 2 clips and remove the inner side garnish. BO4033 29. REMOVE SLIDING ROOF GLASS (a) Remove the 6 nuts and shims. HINT: Make sure of the number of shims. (b) Pull the glass upward to remove it. 30. (a) (b) REMOVE DRIP CHANNEL Remove the 2 screws. Pull the channel forwards to remove it. 31. REMOVE WIND DEFLECTOR Remove the 4 screws and wind deflector. 32. REMOVE SLIDING ROOF HOUSING (a) Disconnect the drain hose. (b) Remove the 3 nuts, 12 screw and housing. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BO−66 BODY − SLIDING ROOF 33. ADJUST DRIVE RAIL HINT: Adjust the drive rail to a closed and tilted down position. Using a screwdriver, slide the link forward or backward to align the 2 marks, as shown. 34. (a) (b) (c) Point Marks (d) (e) (f) 35. (a) (b) ADJUST AND INSTALL DRIVE GEAR ASSEMBLY Remove the screw and cam plate cover. Remove the large screw, washers and shims. Turn the drive shaft by screwdriver to align the housing and gear point mark, as shown. Install the cam plate cover with the screw. Install the drive gear assembly with 4 bolts. Connect the connector. INSTALL DRIVE GEAR CONTROL RELAY AND BRACKET Install the bracket with 2 bolts. Install the drive gear control relay with the bolt, then connect the connector. BO4047 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BO−67 BODY − SLIDING ROOF DISASSEMBLY 1. BO394−01 (a) (b) (c) DISCONNECT SLIDING ROOF GUIDE RAIL AND CABLE GUIDE CASING Remove the screw and guide rail cover. Remove the screw. Pull out the cable guide casing. 2. (a) (b) (c) REMOVE SLIDING GUIDE RAIL Make the drive cable to the front edge. Remove the 4 screws and both side drive rails. Remove the sunshade trim. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BO−68 BODY − SLIDING ROOF BO391−01 INSPECTION 1. (a) (b) (c) (d) BO5152 INSPECT SLIDING ROOF GLASS ALIGNMENT Start the engine and check the operation time of the sliding roof. Operation time: Approx. 5 sec. Check for abnormal noise or binding during operation. With the sliding roof fully closed, check for water leakage. Check for a difference in level between the sliding roof weatherstrip and roof panel. Front End 0.9 − 3.9 mm (0.035 − 0.154 in.) Rear End 0.9 − 3.9 mm (0.035 − 0.154 in.) 2. If the sliding roof does not operate: ADJUST SLIDING ROOF GLASS ALIGNMENT (a) Remove the control switch cover. (b) Remove the large screw inside. NOTICE: Be careful not to lose the spring washer or shim. (c) Manually operate the moon roof by inserting a special crank−shaped screwdriver into the hole and turning the drive shaft. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BO−69 BODY − SLIDING ROOF ADJUSTMENT BO392−01 1. REMOVE SLIDING ROOF GARNISHES Before making adjustments, remove the left and right sliding roof garnishes. HINT: After adjustment, reinstall the sliding roof garnishes. BO4033 2. ADJUST LEVEL DIFFERENCE Adjust by increasing or decreasing the number of shims between the bracket and sliding roof. 3. (a) ADJUST FORWARD OR REARWARD Adjust by loosening the sliding roof installation nuts, and move the sliding roof bracket forwards and backwards. (b) When the front or rear alignment is not correct, remove the glass and adjust the drive rail. Using a screwdriver, slide the link forwards or backwards to align the 2 marks, as shown in the illustration. Slide the bracket to the forefront with your hand. (c) (d) 4. ADJUST RIGHT OR LEFT Adjust by loosening the sliding roof rear shoe installation nuts, and move the sliding roof to the right and left. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BO−70 BODY 5. − SLIDING ROOF ADJUST LEFT/RIGHT CLEARANCE Adjust by loosening the sliding roof installation nuts and readjust the sliding roof to the proper position. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BO−71 BODY − SLIDING ROOF BO395−01 REASSEMBLY Reassembly is in the reverse order of disassembly (See page BO−67). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BO−72 BODY − SLIDING ROOF BO396−01 INSTALLATION Installation is in the reverse order of removal (See pageBO−63 ). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BO−73 BODY − INSTRUMENT PANEL INSTRUMENT PANEL BO397−01 COMPONENTS 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 1307 Brought to you by BirfMark BO−74 BODY − INSTRUMENT PANEL 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 1308 Brought to you by BirfMark BO−75 BODY − INSTRUMENT PANEL HINT: Screw shapes and size are indicated in the table below.The code (A − N) correspond to those indicated on the previous page. 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 1309 Brought to you by BirfMark BO−76 BODY − INSTRUMENT PANEL REMOVAL BO398−01 1. 2. 3. 4. REMOVE REMOVE REMOVE REMOVE STEERING WHEEL (See page SR−11) COLUMN COVER HOOD LOCK RELEASE LEVER FUEL LID RELEASE LEVER 5. 6. 7. 8. 9. REMOVE FUSE BOX OPENING COVER REMOVE LOWER FINISH PANEL REMOVE LOWER INSTRUMENT PANEL REMOVE NO. 2 HEATER TO REGISTER DUCT LOOSEN DLC 3 AND FUSE BLOCK 10. 11. REMOVE NO. 2 CENTER CLUSTER FINISH PANEL REMOVE STEERING COLUMN (See page SR−11) 12. 13. REMOVE CLUSTER FINISH PANEL REMOVE COMBINATION METER 14. REMOVE CENTER CLUSTER FINISH PANEL WITH CLOCK 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BO−77 BODY 15. (a) − INSTRUMENT PANEL REMOVE CENTER CLUSTER FINISH PANEL WITH HEATER CONTROL ASSEMBLY Using a screwdriver, take off the 2 claws, then remove the cup holder hole cover. HINT: Tape the screwdriver tip before use. (b) Take off the ashtray. (c) Remove the center cluster finish panel with heater control assembly, then disconnect the connectors. (d) 16. 17. 18. 19. Remove the 2 screws and heater control assembly from the center cluster finish panel. REMOVE RADIO REMOVE GLOVE COMPARTMENT DOOR REMOVE SPEAKER PANEL AND SPEAKER REMOVE FRONT AND REAR CONSOLE BOX 20. DISCONNECT AIRBAG CONNECTOR (a) Remove the airbag connector from the airbag bracket. NOTICE: When handling the airbag connector, take care not to damage the airbag wire harness. (b) Disconnect the airbag connector. 21. (a) (b) REMOVE INSTRUMENT PANEL Remove the 5 screws and 9 bolts. Remove the instrument panel. Torque: 20 N·m (210 kgf·cm, 15 ft·lbf) for passenger airbag bolts 22. (a) REMOVE INSTRUMENT PANEL REINFORCEMENT Remove the 2 bolts and lower instrument panel reinforcement. Remove the 2 bolts, 2 nuts and No. 1 brace. Remove the 4 bolts, 4 nuts and instrument panel reinforcement. (b) (c) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BO−78 BODY − INSTRUMENT PANEL DISASSEMBLY 1. 2. 3. 4. 5. 6. (a) BO399−01 REMOVE GLOVE COMPARTMENT DOOR REINFORCEMENT REMOVE NO. 4 HEATER TO REGISTER DUCT REMOVE NO. 5 HEATER TO REGISTER DUCT REMOVE NO. 2 REGISTER REMOVE GLOVE COMPARTMENT DOOR LOCK STRIKER PLATE REMOVE FRONT PASSENGER AIRBAG ASSEMBLY (See page RS−22) Remove the 4 bolts and 2 nuts, and remove front passenger airbag assembly. (b) Pry up the 6 clips shown in the illustration and remove the airbag door. CAUTION: S Do not store the front passenger airbag assembly with the airbag deployment direction facing down. S Never disassemble the front passenger airbag assembly. 7. REMOVE NO. 3 CONSOLE MOUNTING BRACKET 8. REMOVE NO. 1 HEATER TO REGISTER DUCT 9. REMOVE NO. 2 STAY 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BO−79 BODY − INSTRUMENT PANEL BO39A−01 REASSEMBLY Reassembly is in the reverse order of disassembly (See page BO−78). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BO−80 BODY − INSTRUMENT PANEL BO39B−01 INSTALLATION Installation is in the reverse order of removal (See page BO−76). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BO−81 BODY − SIDE STEP SIDE STEP BO39C−01 COMPONENTS 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 1315 Brought to you by BirfMark BO−82 BODY − FRONT SEAT (Power Adjuster Type) FRONT SEAT (Power Adjuster Type) BO39E−01 COMPONENTS 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 1316 Brought to you by BirfMark BO−83 BODY − FRONT SEAT (Power Adjuster Type) 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 1317 Brought to you by BirfMark BO−84 BODY − FRONT SEAT (Power Adjuster Type) DISASSEMBLY BO48R−01 1. REMOVE FRONT SEAT HEADREST 2. REMOVE SIDE SUPPORT ADJUSTER KNOB Using a screwdriver, remove the snap ring and side support adjuster knob. 3. REMOVE SEATBACK BOARD (a) Remove the 2 screws. (b) Slide the board downward to remove it. 4. (a) (b) 5. 6. 7. REMOVE FRONT SEATBACK ASSEMBLY Using a hog ring pliers, remove the hog ring backward of seatback. Remove the 4 bolts and front seatback assembly. Torque: 30 N·m (300 kgf·cm, 22 ft·lbf) REMOVE FRONT SEAT CUSHION INNER SHIELD REMOVE FRONT SEAT INNER BELT REMOVE FRONT SEAT CUSHION SHIELD 8. (a) REMOVE FRONT SEAT CUSHION Remove the 4 bolts. Torque: 30 N·m (300 kgf·cm, 22 ft·lbf) (b) Disconnect the connector, then remove the front seat cushion. 9. REMOVE SEAT CUSHION REAR PROTECTOR 10. REMOVE RECLINING ADJUSTER INSIDE COVER Remove the 4 screws and reclining adjuster inside cover LH and RH. 11. REMOVE POWER ADJUST FRONT SHIELD Remove the 2 screws and front shield. 12. REMOVE SLIDE MOTOR (a) Using the 5.0 mm (0.20 in.) hexagon wrench, remove the 4 housing bracket screws. Torque: 10 N·m (100 kgf·cm, 7.0 ft·lbf) (b) Hold the front seat horizontal jack screw with a plier, and remove the 2 nuts and 2 washers. Torque: 2.0 N·m (20 kgf·cm, 17 in.·lbf) HINT: At the time of installation, apply adhesive to nut. Part No. 08833 − 00070, THREE BOND 1324 or equivalent 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BO−85 BODY − FRONT SEAT (Power Adjuster Type) (c) Remove the 4 screws and 2 vertical adjuster bushes. (d) Remove the 4 bolts, slide motor, front seat slide housing and front seat horizontal jack screw. Torque: 19 N·m (200 kgf·cm, 14 ft·lbf) Loosen the seat adjuster nut, then remove the slide motor. (e) 13. (a) REMOVE REAR VERTICAL MOTOR Remove the 2 E−rings, and disconnect the No. 1 vertical seat link. (b) Remove the 4 bolts, vertical rod hold bracket RH and vertical rod hold bracket LH. Torque: 20 N·m (210 kgf·cm, 15 ft·lbf) (c) Using the 5.0 mm (0.20 in.) hexagon wrench, remove the 2 housing support bracket screws. Torque: 10 N·m (100 kgf·cm, 7.0 ft·lbf) Hold the No. 2 vertical travel jack screw with a plier, remove the nut and washer. Torque: 2.0 N·m (20 kgf·cm, 17 in.·lbf) (d) HINT: At the time of reassembly, apply adhesive to nut. Part No. 08833−00070, THREE BOND 1324 or equivalent 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BO−86 BODY − FRONT SEAT (Power Adjuster Type) (e) Remove the 2 screws, vertical adjuster bush, rear vertical motor and No. 2 vertical seat link. 14. (a) REMOVE FRONT VERTICAL MOTOR Using the 5.0 mm (0.20 in.) hexagon wrench, and remove the 2 housing support bracket screws. Torque: 10 N·m (100 kgf·cm, 7.0 ft·lbf) Hold the No. 1 vertical travel jack screw with a plier, remove the nut and washer. (b) HINT: At the time of reassembly, apply adhesive to nut. Part No. 08833−00070, THREE BOND 1324 or equivalent Torque: 2.0 N·m (20 kgf·cm, 15 ft·lbf) (c) Remove the 2 screws, vertical adjuster bush, front vertical motor and No. 1 vertical seat link. 15. (a) REMOVE FRONT SEAT TRACK Remove the 2 bolts and front seat motor side housing. Torque: 20 N·m (210 kgf·cm, 15 ft·lbf) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BO−87 BODY (b) (c) 16. 17. 18. − FRONT SEAT (Power Adjuster Type) Remove the 2 bolts, seat track inner reinforcement, then separate the seat track RH and LH. Torque: 20 N·m (210 kgf·cm, 15 ft·lbf) Remove the reclining connecting rod. REMOVE SEAT WIRE REMOVE RECLINING MOTOR REMOVE RECLINING HINGE COVER 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BO−88 BODY − FRONT SEAT (Power Adjuster Type) BO39H−01 REASSEMBLY Reassembly is in the reverse order of disassembly (See page BO−84). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BO−89 BODY − FRONT SEAT (Manual Adjuster Type) FRONT SEAT (Manual Adjuster Type) BO39D−01 COMPONENTS 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 1323 Brought to you by BirfMark BO−90 BODY − REAR NO.1 SEAT REAR NO.1 SEAT BO39J−01 COMPONENTS 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 1324 Brought to you by BirfMark BO−91 BODY − REAR NO.2 SEAT REAR NO.2 SEAT BO39K−01 COMPONENTS 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 1325 Brought to you by BirfMark BO−92 BODY − SEAT BELT SEAT BELT BO39L−01 COMPONENTS 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 1326 Brought to you by BirfMark BO−93 BODY − SEAT BELT SEAT BELT INSPECTION BO0632 15° 45° BO0633 BO39M−01 CAUTION: Replace the seat belt assembly (outer belt, inner belt, bolts, nuts or sill−bar) if it has been used in a severe impact. The entire assembly should be replaced even if damage is not obvious. 1. All seat belts: RUNNING TEST (IN SAFE AREA) (a) Fasten the front seat belts. (b) Drive the car at 10 mph (16 km/h) and make a very hard stop. Check that the belt locks and cannot be extended at this time. HINT: Conduct this test in a safe area. If the belt does not lock, remove the belt mechanism assembly and conduct the following static check. Also, whenever installing a new belt assembly, verify the proper operation before installation. 2. Driver’s seat belt (ELR): STATIC TEST (a) Make sure that the belt locks when pulled out quickly. (b) Remove the locking retractor assembly. (c) Tilt the retractor slowly. (d) Make sure that the belt can be pulled out at a tilt of 15 degrees or less, and cannot be pulled out at over 45 degrees of tilt. If a problem is found, replace the assembly. 3. Except driver’s seat belt (ALR/ELR): STATIC TEST (a) Make sure that the belt locks when pulled out quickly. (b) Remove the locking retractor assembly. (c) Pull out the whole belt and measure the length of the whole belt. Then retract the belt slightly and pull it out again. (d) Make sure that the belt cannot be extended further. If a problem is found, replace the assembly. (e) Retract the whole belt, then pull it out to the full length minus 200 mm (7.87 in.). (f) Tilt the retractor slowly. (g) Make sure that the belt can be pulled out at a tilt of 15 degrees or less, and cannot be pulled out at over 45 degrees of tilt. If a problem is found, replace the assembly. Full Belt Length minus 200 mm (7.87 in.) N10070 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BR−1 BRAKE − BRAKE SYSTEM BRAKE SYSTEM BR1CC−01 GENERAL DESCRIPTION S S S Care must be taken to replace each part properly as it could affect the performance of the brake system and result in a driving hazard. Replace the parts with parts of the same part number or equivalent. It is very important to keep parts and the area clean when repairing the brake system. If the vehicle is equipped with a mobile communication system, refer to the precaution in the IN section. 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 983 Brought to you by BirfMark BR−2 BRAKE − TROUBLESHOOTING TROUBLESHOOTING BR1CD−01 PROBLEM SYMPTOMS TABLE Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely cause of the problem. Check each part in order. If necessary, replace these parts. Symptom Low pedal or spongy pedal Suspect Area See page 4. Fluid leaks for brake system 5. Air in brake system 6. Piston seals: worn or damaged − − BR−33 BR−33 BR−9 BR−20 7. Master cylinder: faulty 8. Booster push rod: out of adjustment 1. 2. 3. 4. Brake pedal freeplay: minimal Parking brake lever travel: out of adjustment Parking brake wire: sticking Pad: cracked or distorted 5. Piston: stuck Brake drag 6. Piston: frozen 7. Tension or return spring: faulty 8. Booster push rod: out of adjustment 9. . Vacuum leaks for booster system 10.. Master cylinder: faulty 1. Piston: stuck BR−33 BR−33 BR−21 BR−30 BR−33 BR−33 BR−33 BR−33 BR−21 BR−30 2. Pad: oily Brake pull BR−6 BR−8 − BR−21 BR−30 BR−33 BR−33 BR−33 BR−33 BR−39 BR−20 BR−18 BR−9 3. Piston: frozen 4. Disc: Scored 5. Pad: cracked or distorted 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 984 Brought to you by BirfMark BR−3 BRAKE − TROUBLESHOOTING 1. Fluid leaks for brake system 2. Air in brake system 3. Pad: worn − − BR−21 BR−30 BR−21 BR−30 BR−21 BR−30 BR−21 BR−30 BR−21 BR−30 BR−20 BR−18 4. Pad: cracked or distorted Hard pedal but brake inefficient 5. Pad: oily 6. Pad: glazed 7. Disc: scored 8. Booster push rod: out of adjustment 9. Vacuum leaks for booster system 1. Pad: cracked or distorted BR−21 BR−30 BR−33 BR−33 BR−33 BR−33 BR−30 BR−33 BR−21 BR−30 BR−21 BR−30 BR−39 BR−21 BR−30 BR−39 2. Installation bolt: loosen 3. Disc: scored Noise from brake 4. Pad support plate: loosen 5. Sliding pin: worn 6. Pad: dirty 7. Pad: glazed 8. Tension or return spring: faulty 9. Anti−squeal shim: damaged 10.. Hold−down spring: damaged 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 985 Brought to you by BirfMark BR−4 BRAKE − BRAKE FLUID BRAKE FLUID BR1CE−01 BLEEDING HINT: If any work is done on the brake system or if air is suspected in the brake lines, bleed the system of air. NOTICE: Do not let brake fluid remain on a painted surface. Wash it off immediately. 1. FILL BRAKE RESERVOIR WITH BRAKE FLUID Check the fluid level in the reservoir after bleeding each wheel. Add fluid, if necessary. Fluid: SAE J1703 or FMVSS No.116 DOT3 R13494 2. BLEED MASTER CYLINDER HINT: If the master cylinder has been disassembled or if the reservoir becomes empty, bleed the air from the master cylinder. (a) Disconnect the brake lines from the master cylinder. (b) Slowly depress the brake pedal and hold it. (c) (d) Block off the outlet plugs with your fingers, and release the brake pedal. Repeat (b) and (c) 3 or 4 times. 3. CONNECT VINYL TUBE TO BRAKE CALIPER BLEEDER PLUG Insert other end of the tube in a half−full container of brake fluid. NOTICE: Begin bleeding air from the brake caliper with the longest hydraulic line. 4. BLEED BRAKE LINE (a) Slowly depress the brake pedal several times. R00252 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 986 Brought to you by BirfMark BR−5 BRAKE (b) (c) 5. 6. − BRAKE FLUID While an assistant depresses the pedal, loosen the bleeder plug until fluid starts to run out. Then tighten the bleeder plug. Repeat this procedure until there are no more air bubbles in the fluid. Bleeder plug tightening torque: 11 N·m (110 kgf·cm, 8 ft·lbf) REPEAT PROCEDURE FOR EACH WHEEL BLEED LSP & BV 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 987 Brought to you by BirfMark BR−6 BRAKE − BRAKE PEDAL BRAKE PEDAL Stop Light Switch ON−VEHICLE INSPECTION Push Rod 1. 2. (a) (b) (c) (d) (e) (f) Pedal Height (g) BR1CF−04 CHECK PEDAL HEIGHT Pedal height from dash panel: 167.5 − 177.5 mm (6.594 − 6.988 in.) IF NECESSARY, ADJUST PEDAL HEIGHT Disconnect the connector from the stop light switch. Loosen the stop light switch lock nut and remove the stop light switch. Loosen the push rod lock nut. Adjust the pedal height by turning the pedal push rod. Tighten the push rod lock nut. Torque: 25 N·m (260 kgf·cm, 19 ft·lbf) Install the stop light switch and turn it until it lightly contacts the pedal stopper. Turn the stop light switch back one turn. BR3295 (h) A (i) (j) (k) BR4980 (l) 3. (a) (b) Pedal Freeplay BR0016 Check the clearance (A) between the stop light switch and pedal. Clearance: 0.5 − 2.4 mm (0.020 − 0.094 in.) Tighten the stop light switch lock nut. Connect the connector to the stop light switch. Check that the stop lights come on when the brake pedal is depressed, and go off when the brake pedal is released. earance (A) between the stop light switch and the pedal stopper has been adjusted correctly, the pedal freeplay will meet the specifications. CHECK PEDAL FREEPLAY Stop the engine and depress the brake pedal several times until there is no more vacuum left in the booster. Push in the pedal by hand until the beginning of the second resistance is felt. Measure the distance. Pedal freeplay: 3 − 6 mm (0.12 − 0.24 in.) HINT: The freeplay to the 1st resistance is due to the play between the clevis and pin. This is magnified up to 3 − 6 mm (0.12 − 0.24 in.) at the pedal. 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 988 Brought to you by BirfMark BR−7 BRAKE − BRAKE PEDAL If incorrect, check the stop light switch clearance. If the clearance is OK, then troubleshoot the brake system. 4. Pedal Reserve Distance a CHECK PEDAL RESERVE DISTANCE Release the parking brake. With the engine running, depress the pedal and measure the pedal reserve distance, as shown. Pedal reserve distance, ’a’, at 490 N (50 kgf, 110.2lbf): More than 68 mm (2.68 in.) If the reserve distance incorrect, troubleshoot the brake system. S S BR3297 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 989 Brought to you by BirfMark BR−8 BRAKE − PARKING BRAKE LEVER PARKING BRAKE LEVER ON−VEHICLE INSPECTION BR1CG−01 1. BR4774 BR4775 CHECK THAT PARKING BRAKE LEVER TRAVEL IS CORRECT Pull the parking brake lever all the way up, and count the number of clicks. Parking brake lever travel at 196 N (20 kgf, 44.1 lbf): 7 − 9 clicks If incorrect, adjust the parking brake. 2. IF NECESSARY, ADJUST PARKING BRAKE HINT: Before adjusting the parking brake, make sure that the rear brake shoe clearance has been adjusted. For shoe clearance adjustment (See page BR−42). (a) Remove the rear console box. (b) Loosen the lock nut and turn the adjusting nut until the lever travel is correct. (c) Tighten the lock nut. Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf) (d) Install the rear console box. 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 990 Brought to you by BirfMark BR-9 BRAKE - BRAKE MASTER CYLINDER BRAKE MASTER CYLINDER BR1CH-01 COMPONENTS 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BR-10 BRAKE - BRAKE MASTER CYLINDER BR1CI-01 REMOVAL 1. DISCONNECT LEVEL WARNING SWITCH CONNECTOR 2. TAKE OUT FLUID WITH SYRINGE NOTICE: Do not let brake fluid remain on a painted surface. Wash it off immediately. 3. DISCONNECT BRAKE LINES Using SST, disconnect the 4 brake lines from the master cylinder and 3-way. SST 09023-00100 Torque: 15 N·m (155 kgf·cm, 11 ft·lbf) R13497 4. (a) (b) (c) REMOVE MASTER CYLINDER Remove the 4 nuts. Torque: 13 N·m (130 kgf·cm, 9 ft·lbf) Remove the 3-way, check valve bracket, wire harness clamp and bracket. Pull out the master cylinder and gasket. R13591 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BR-1 1 BRAKE - BRAKE MASTER CYLINDER BR1CJ-01 DISASSEMBLY 1. (a) (b) 2. 3. REMOVE RESERVOIR Remove the set screw and pull out the reservoir. Torque: 1.7 N·m (17.5 kgf·cm, 15.2 in.·lbf) Remove the cap and strainer from the reservoir. REMOVE 2 GROMMETS REMOVE BOLT AND CLAMP FROM CYLINDER BODY 4. PLACE CYLINDER IN VISE 5. REMOVE PISTON STOPPER BOLT Using a screwdriver, push the pistons in all the way and remove the piston stopper bolt and gasket. HINT: Tape the screwdriver tip before use. Torque: 10 N·m (100 kgf·cm, 7 ft·lbf) 6. (a) REMOVE 2 PISTONS AND SPRINGS Push in the piston with a screwdriver and remove the snap ring with snap ring pliers. HINT: Tape the screwdriver tip before use. (b) Remove the No.1 piston and spring by hand, pulling straight out, not at an angle. NOTICE: If pulled out and installed at an angle, there is a possibly that the cylinder bore could be damaged. NOTICE: Be careful not to damage the rubber lips on the pistons. (c) Place a rag and 2 wooden blocks on the work table, and lightly tap the cylinder flange against the block edges until the No.2 piston drops out of the cylinder. HINT: Make sure that the distance (A) from the rag to the top of the blocks is at least 100 mm (3.94 in.). A R12236 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BR-12 BRAKE - BRAKE MASTER CYLINDER BR1CK-01 INSPECTION HINT: Clean the disassembled parts with compressed air. 1. INSPECT CYLINDER BORE FOR RUST OR SCORING 2. INSPECT CYLINDER FOR WEAR OR DAMAGE If necessary, clean or replace the cylinder. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BR-13 BRAKE - BRAKE MASTER CYLINDER BR1CL-01 REASSEMBLY Reassembly is in the reverse order of disassembly. NOTICE: Apply lithium soap base glycol grease to the rubber parts indicated by the arrows (See page BR-9 ). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BR-14 BRAKE - BRAKE MASTER CYLINDER BR1CM-01 INSTALLATION Installation is in the reverse order of removal (See page BR-9 ). HINT:
Before installation, adjust length of brake booster push rod (See page BR-18 ).
After installation, fill brake reservoir with brake fluid, bleed brake system (See page BR-4 ).
Check for leaks, check and adjust brake pedal (See page BR-6 ). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BR-15 BRAKE - BRAKE BOOSTER ASSEMBLY BRAKE BOOSTER ASSEMBLY BR1CN-01 OPERATION 1. (a) (b) 2. (a) (b) BR2238 OPERATING CHECK Depress the brake pedal several times with the engine off and check that there is no change in the pedal reserve distance. Depress the brake pedal and start the engine. If the pedal goes down slightly, operation is normal. AIR TIGHTNESS CHECK Start the engine and stop it after 1 or 2 minutes. Depress the brake pedal several times slowly. If the pedal goes down furthest the 1st time, but gradually rises after the 2nd or 3rd time, the booster is air tight. Depress the brake pedal while the engine is running, and stop the engine with the pedal depressed. If there is no change in the pedal reserve travel after holding the pedal for 30 seconds, the booster is air tight. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BR-16 BRAKE - BRAKE BOOSTER ASSEMBLY BR1CO-01 COMPONENTS 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BR−17 BRAKE − BRAKE BOOSTER ASSEMBLY BRAKE BOOSTER ASSEMBLY OPERATION 1. (a) (b) BR2237 2. (a) (b) BR2238 BR1NM−01 OPERATING CHECK Depress the brake pedal several times with the engine off and check that there is no change in the pedal reserve distance. Depress the brake pedal and start the engine. If the pedal goes down slightly, operation is normal. AIR TIGHTNESS CHECK Start the engine and stop it after 1 or 2 minutes. Depress the brake pedal several times slowly. If the pedal goes down furthest the 1st time, but gradually rises after the 2nd or 3rd time, the booster is air tight. Depress the brake pedal while the engine is running, and stop the engine with the pedal depressed. If there is no change in the pedal reserve travel after holding the pedal for 30 seconds, the booster is air tight. 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 999 Brought to you by BirfMark BR−18 BRAKE − BRAKE BOOSTER ASSEMBLY BR1CO−02 COMPONENTS 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BR−19 BRAKE − BRAKE BOOSTER ASSEMBLY REMOVAL 1. 2. S S S S 3. (a) (b) BR1CP−03 REMOVE MASTER CYLINDER (See page BR−9) REMOVE THESE PARTS: Return spring Clip and clevis pin Clevis Vacuum hose REMOVE BRAKE BOOSTER Remove the 4 booster installation nuts. Remove the booster and gasket. BR3753 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BR−20 BRAKE − BRAKE BOOSTER ASSEMBLY INSTALLATION 1. (a) (b) (c) (d) (e) SST BR1CQ−01 INSTALL BRAKE BOOSTER Install the booster and a new gasket. Install the clevis to the operating rod. Install and torque the booster installation nuts. Torque: 13 N·m (130 kgf·cm, 9 ft·lbf) Install the clevis pin into the clevis and brake pedal, and install the clip to the clevis pin. Install the pedal return spring. 2. (a) (b) ADJUST LENGTH OF BOOSTER PUSH ROD Install a new gasket on the master cylinder. Set the SST on the gasket, and lower the pin until its tip slightly touches the piston. SST 09737−00010 (c) Turn the SST upside down, and set it on the booster. SST 09737−00010 Measure the clearance between the booster push rod and pin head (SST). Clearance: 0 mm (0 in.) Adjust the booster push rod length until the push rod lightly touches the pin head. INSTALL MASTER CYLINDER (See page BR−9) CONNECT VACUUM HOSE TO BRAKE BOOSTER FILL BRAKE RESERVOIR WITH BRAKE FLUID AND BLEED BRAKE SYSTEM (See page BR−4) CHECK FOR FLUID LEAKAGE CHECK AND ADJUST BRAKE PEDAL (See page BR−6) DO OPERATIONAL CHECK (See page BR−17) Gasket BR3976 SST (d) (e) R11347 3. 4. 5. 6. 7. 8. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BR−21 BRAKE − FRONT BRAKE PAD FRONT BRAKE PAD BR1CR−01 COMPONENTS 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 1003 Brought to you by BirfMark BR−22 BRAKE − FRONT BRAKE PAD REPLACEMENT 1. BR1CS−04 REMOVE FRONT WHEEL 2. INSPECT PAD LINING THICKNESS Check the pad thickness and replace pads if not within the specification. Minimum thickness: 1.0 mm (0.039 in.) 3. REMOVE THESE PARTS: Clip 2 pins Anti−rattle spring 2 pads 4 anti−squeal shims NOTICE: The anti−rattle spring and clip can be used again provided that they have sufficient rebound, no deformation, cracks or wear, and have had all rust, dirt and foreign particles cleaned off. 4. CHECK DISC THICKNESS AND RUNOUT (See page BR−27) 5. INSTALL NEW PADS NOTICE: When replacing worn pads, the anti−squeal shims must be replaced together with the pads. (a) Draw out a small amount of brake fluid from the reservoir. S S S S S (b) Press in the pistons with a hammer handle or an equivalent. HINT: S S (c) Always change the pad on one wheel at a time as there is a possibility of the opposite piston flying out. If the piston is difficult to push in, loosen the bleeder plug and push in the piston while letting some brake fluid escape. Install the 2 anti−squeal shims to new pads. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BR−23 BRAKE − FRONT BRAKE PAD HINT: Apply disc brake grease to both sides of the inner anti−squeal shims (See page BR−21). (d) Install the 2 pads. HINT: Apply disc brake grease to the caliper indicated by the arrows (See page BR−33). NOTICE: Do not allow oil or grease to get on the rubbing face. 6. INSTALL ANTI−RATTLE SPRING AND 2 PINS 7. INSTALL CLIP 8. INSTALL FRONT WHEEL 9. CHECK THAT FLUID LEVEL IS AT MAX LINE 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BR−24 BRAKE − FRONT BRAKE CALIPER FRONT BRAKE CALIPER BR1CT−01 COMPONENTS 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 1006 Brought to you by BirfMark BR−25 BRAKE − FRONT BRAKE CALIPER REMOVAL 1. (a) (b) BR1CU−03 DISCONNECT FLEXIBLE HOSE Remove the union bolt and 2 gaskets from the caliper, then disconnect the flexible hose from the caliper. Torque: 30 N·m (310 kgf·cm, 22 ft·lbf) Use a container to catch the brake fluid as it drains out. 2. REMOVE CALIPER Remove the 2 mounting bolts and caliper. Torque: 123 N·m (1,250 kgf·cm, 90 ft·lbf) 3. REMOVE THESE PARTS: S Clip S 2 pins S Anti−rattle spring S 2 pads S 4 anti−squeal shims 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BR−26 BRAKE − FRONT BRAKE CALIPER DISASSEMBLY BR1CV−04 1. REMOVE CYLINDER BOOT SET RINGS AND BOOTS Using a screwdriver, remove the 4 cylinder boot set rings and boots. BR2008 170 mm (6.70 in.) 50 mm (1.97 in.) 2. (a) REMOVE PISTONS FROM CYLINDER Prepare the wooden plate to hold the pistons. 16 mm (0.63 in.) Z09007 (b) Place the plate between the pistons and insert a pad at one side. (c) Use compressed air to remove the pistons alternately from the cylinder. CAUTION: Do not place your fingers in front of the pistons when using compressed air. BR0213 3. REMOVE PISTON SEALS Using a screwdriver, remove the 4 piston seals from the cylinder. BR2009 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BR−27 BRAKE − FRONT BRAKE CALIPER INSPECTION BR1CX−03 1. MEASURE PAD LINING THICKNESS Using a ruler, measure the pad lining thickness. Standard thickness: 9.5 mm (0.374 in.) Minimum thickness: 1.0 mm (0.039 in.) Replace the pad if the thickness is less than the minimum (the 1.0 mm slit is no longer visible), or if it shows signs of uneven wear. BR0251 2. MEASURE DISC THICKNESS Using a micrometer, measure the disc thickness. Standard thickness: 32.0 mm (1.260 in.) Minimum thickness: 30.0 mm (1.181 in.) If the disc is scored or worn, or if its thickness is less than the minimum, repair or replace the disc. 3. MEASURE DISC RUNOUT Using a dial indicator, measure the disc runout at a position 10 mm (0.39 in.) from the outside edge. Maximum disc runout: 0.15 mm (0.0059 in.) If the runout is greater than the maximum, replace the disc or grind it on a ”On−Car” brake lathe. HINT: Before measuring the runout, confirm that the front hub bearing play is within the specification. 4. IF NECESSARY, REPLACE DISC (a) Remove the front axle hub (See page SA−7). (b) Remove the disc from the axle hub. (c) Install a new disc and torque the bolts. Torque: 74 N·m (750 kgf·cm, 54 ft·lbf) (d) Install the axle hub and adjust the front bearing preload (See page SA−9). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BR−28 BRAKE − FRONT BRAKE CALIPER BR1CW−01 REASSEMBLY Reassembly is in the reverse order of disassembly (See page BR−26). NOTICE: Apply lithium soap base glycol grease to the parts indicated by the arrows (See page BR−33). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BR−29 BRAKE − FRONT BRAKE CALIPER BR1CY−01 INSTALLATION Installation is in the reverse order of removal (See page BR−25). HINT: After installation, fill the brake reservoir with brake fluid, bleed brake system (see page BR−4) and check for leaks. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BR−30 BRAKE − REAR BRAKE PAD REAR BRAKE PAD BR1CZ−02 COMPONENTS 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 1012 Brought to you by BirfMark BR−31 BRAKE − REAR BRAKE PAD REPLACEMENT BR1D0−03 1. REMOVE REAR WHEEL Remove the wheel and temporarily fasten the disc with the hub nuts. 2. INSPECT PAD LINING THICKNESS Check the pad thickness through the caliper inspection hole and replace pads if the thickness is not within the specification. Minimum thickness: 1.0 mm (0.039 in.) 3. (a) (b) REMOVE BRAKE CALIPER Remove the sliding main pin and sliding sub pin. Remove the caliper and suspend it so the hose is not stretched. HINT: Do not disconnect the flexible hose. 4. REMOVE THESE PARTS: (a) 2 brake pads (b) Anti−squeal shim (c) 4 pad support plates (d) 2 pad wear indicator plates NOTICE: The pad support plates can be used again provided that they have sufficient rebound, no deformation, cracks or wear, and have had all rust, dirt and foreign particles cleaned off. 5. CHECK DISC THICKNESS AND RUNOUT (See page BR−36) 6. INSTALL PAD SUPPORT PLATES 7. INSTALL NEW PADS NOTICE: When replacing worn pads, the anti−squeal shim and wear indicator plates must be replaced together with the pads. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BR−32 BRAKE − REAR BRAKE PAD (a) (b) (c) Install pad wear indicator plate to each pads. Install the anti−squeal shim to the outer pad. Install the 2 pads so the wear indicator plate is facing upward. NOTICE: Do not allow oil or grease to get on the rubbing face. 8. INSTALL CALIPER (a) Draw out a small amount of brake fluid from the reservoir. (b) Press in piston with a hammer handle or an equivalent. HINT: Always change the pads on one wheel at a time as there is a possibility of the opposite piston flying out. (c) Install the caliper carefully so the boot is not wedged. (d) Install and torque the sliding main pin and sub pin. Torque: 88 N·m (900 kgf·cm, 65 ft·lbf) 9. INSTALL REAR WHEEL 10. CHECK THAT FLUID LEVEL IS AT MAX LINE 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BR−33 BRAKE − REAR BRAKE CALIPER REAR BRAKE CALIPER BR1D1−01 COMPONENTS 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 1015 Brought to you by BirfMark BR−34 BRAKE − REAR BRAKE CALIPER BR1D2−01 REMOVAL 1. (a) DISCONNECT FLEXIBLE HOSE Remove the union bolt and 2 gaskets from the caliper, then disconnect the flexible hose from the caliper. Torque: 30 N·m (310 kgf·cm, 22 ft·lbf) (b) Use a container to catch the brake fluid as it drains out. 2. REMOVE CALIPER Remove the 2 sliding pins and caliper. Torque: 88 N·m (900 kgf·cm, 65 ft·lbf) 3. REMOVE THESE PARTS: (a) 2 pads with anti−squeal shim (b) 4 pad support plates 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BR−35 BRAKE − REAR BRAKE CALIPER DISASSEMBLY BR1D3−01 1. REMOVE CYLINDER BOOT Using a screwdriver, remove the cylinder boot from the caliper. 2. (a) REMOVE PISTON Place a piece of cloth or similar article between the piston and the caliper. (b) Use compressed air to remove the piston from the cylinder. CAUTION: Do not place your fingers in front of the piston when using compressed air. 3. REMOVE PISTON SEAL Using a screwdriver, remove the piston seal from the cylinder. 4. REMOVE DUST BOOT AND SLIDING BUSHING Using a screwdriver and hammer, tap out dust boot and sliding bushing. HINT: Tape the screwdriver tip before use. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BR−36 BRAKE − REAR BRAKE CALIPER INSPECTION BR1D5−03 1. MEASURE PAD LINING THICKNESS (See step 1. on page BR−27) Standard thickness: 10.0 mm (0.394 in.) Minimum thickness: 1.0 mm (0.039 in.) 2. MEASURE DISC THICKNESS (See page BR−27) Standard thickness: 18.0 mm (0.709 in.) Minimum thickness: 16.0 mm (0.630 in.) 3. MEASURE DISC RUNOUT (See page BR−27) Maximum disc runout: 0.15 mm (0.0059 in.) If the runout is greater than the maximum, adjust the disc runout or grind it on a ”On−Car” brake lathe. 4. IF NECESSARY, REPLACE DISC (a) Remove the torque plate.. (b) Remove the hub nuts of the temporarily installed disc and pull off the disc. (c) Install a new disc and and loosely install the hub nuts. (d) Install the torque plate and tighten the mounting bolts. Torque: 103 N·m (1,050 kgf·cm, 76 ft·lbf) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BR−37 BRAKE − REAR BRAKE CALIPER BR1D4−01 REASSEMBLY Reassembly is in the reverse order of disassembly (See page BR−35). NOTICE: Apply lithium soap base glycol grease to the parts indicated by the arrows (See page BR−33). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BR−38 BRAKE − REAR BRAKE CALIPER BR1D6−01 INSTALLATION Installation is in the reverse order of removal (See page BR−34). HINT: After installation, fill brake reservoir with brake fluid, bleed brake system (See pageBR−4) and check for leaks. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BR−39 BRAKE − PARKING BRAKE PARKING BRAKE BR1D7−01 COMPONENTS 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 1021 Brought to you by BirfMark BR−40 BRAKE − PARKING BRAKE DISASSEMBLY BR1D8−04 1. 2. (a) REMOVE REAR WHEEL REMOVE REAR DISC BRAKE ASSEMBLY Remove the 2 mounting bolts and remove the disc brake assembly. Torque: 88 N·m (900 kgf·cm, 65 ft·lbf) (b) Suspend the disc brake assembly securely. Ensure that the hose is not stretched. 3. REMOVE DISC Place the matchmarks on the disc and rear hub, and remove the disc. HINT: If the disc cannot be removed easily, turn the shoe adjuster until the wheel turns freely. 4. REMOVE TENSION SPRING Using needle−nose pliers, remove the tension spring. 5. REMOVE SHOE RETURN SPRINGS Using SST, remove the shoe return springs. SST 09717−20010 HINT: Using SST, install the front shoe return spring and then install the rear return spring. SST 09718−20010 6. REMOVE SHOE STRUT WITH SPRING 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BR−41 BRAKE 7. (a) (b) (c) 8. (a) (b) (c) 9. (a) (b) (c) (d) (e) (f) (g) (h) (i) − PARKING BRAKE REMOVE REAR SHOE, ADJUSTER AND TENSION SPRING Slide out the rear shoe, and remove the rear shoe and adjuster. Remove the 2 shoe hold−down spring cups, spring and pin. Remove the lower side tension spring. REMOVE FRONT SHOE Slide out the front shoe. Remove the shoe 2 hold−down spring cups, springs and pin. Disconnect the parking brake cable from the parking brake shoe lever. IF NECESSARY, REMOVE AND DISASSEMBLE PARKING BRAKE BELLCRANK ASSEMBLY Using a screwdriver, remove the C−washer. Remove the pin and disconnect the parking brake cable No.2 from the bellcrank. Remove the clip. Remove the pin and clip, then disconnect the parking brake cable. Remove the 2 tension springs. Remove the 2 bolts and parking brake bellcrank assembly. Torque: 13 N·m (130 kgf·cm, 9 ft·lbf) Remove the boot from parking brake bellcrank bracket. Using a screwdriver, remove the C−washer and pin. Remove the parking brake bellcrank from the bell crank bracket. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BR−42 BRAKE − PARKING BRAKE BR1D9−02 INSPECTION 1. INSPECT DISASSEMBLED PARTS Inspect the disassembled parts for wear, rust or damage. 2. MEASURE BRAKE SHOE LINING THICKNESS Using a ruler, measure the thickness of the shoe lining. Standard thickness: 4.0 mm (0.157 in.) Minimum thickness: 1.0 mm (0.039 in.) If the lining thickness is at the minimum thickness or less, or if there is extremely uneven wear, replace the brake shoe. 3. MEASURE BRAKE DISC INSIDE DIAMETER Using a vernier calipers, measure the inside diameter of the disc. Standard inside diameter: 230 mm (9.06 in.) Maximum inside diameter: 231 mm (9.09 in.) Replace the disc if the inside diameter is at the maximum value or more. Replace the disc or grind it with a lathe if the disc is scored or is worn unevenly. BR0897 4. INSPECT PARKING BRAKE LINING AND DISC FOR PROPER CONTACT Apply chalk to the inside surface of the disc, then grind down the brake shoe lining to fit. If the contact between the disc and the brake shoe lining is improper, repair it using a brake shoe grinder or replace the brake shoe assembly. BR0828 5. MEASURE CLEARANCE BETWEEN PARKING BRAKE SHOE AND LEVER Using a feeler gauge, measure the clearance. Standard clearance: Less than 0.35 mm (0.0138 in.) If the clearance is not within the specification, replace the shim with one of the correct size. Shim Clearance R00343 Shim Thickness Shim Thickness 0.3 mm (0.012 in.) 0.9 mm (0.035 in.) 0.6 mm (0.024 in.) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BR−43 BRAKE − PARKING BRAKE 6. (a) (b) IF NECESSARY, REPLACE SHIM Using a screwdriver, remove the C−washer. Remove the parking brake shoe lever, and install the correct size shim. (c) Using needle−nose pliers, install the parking brake shoe lever with a new C−washer. Remeasure the clearance. (d) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BR−44 BRAKE − PARKING BRAKE REASSEMBLY BR1DA−01 Reassembly is in the reverse order of disassembly (See page BR−40). NOTICE: Apply high temperature grease and lithium soap base glycol grease to the parts indicated by the arrows (See page BR−39). 1. ADJUST PARKING BRAKE SHOE CLEARANCE (a) Disconnect the PKB cable from bellcrank and remove the 2 tension springs. (b) Loosen the stopper bolt. (c) Temporarily install the hub nuts. (d) Remove the hole plug. (e) Turn the adjuster and expand the shoes until the disc locks. (f) Return the adjuster 8 notches. (g) Install the hole plug. 2. (a) (b) (c) (d) (e) 3. (a) (b) (c) (d) 4. ADJUST BELLCRANK Pull the bellcrank until all play in the interior linkage is taken up. Screw in the bellcrank adjusting bolt to where it contacts on the dust seal. Loosen it one turn, and lock it at that position with the lock nut. Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf) Install the bellcrank spring. Connect the PKB cable to the bellcrank. BEDDING DOWN PARKING BRAKE SHOES AND DISC Drive the vehicle at about 50 km/h (31 mph) on a safe, level and dry road. With the parking brake release button pushed in, pull on the lever with 88 N (9 kgf, 19.8 lbf) of force. Drive the vehicle for about 400 meters (0.25 mile) in this condition. Repeat this procedure 2 or 3 times. RECHECK AND ADJUST PARKING BRAKE LEVER TRAVEL 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BRAKE − LOAD SENSING PROPORTIONING AND BY−PASS VALVE (LSP & BV) BR−45 ON−VEHICLE INSPECTION BR1DC−04 1. SET REAR AXLE LOAD Rear axle load (include vehicle weight): 1,330 kg (2,932 lb) 2. INSTALL LSPV GAUGE (SST) AND BLEED AIR SST 09709−29018 3. RAISE FRONT BRAKE PRESSURE TO 7,845 kPa (80 kgf/cm2, 1,138 psi) AND CHECK REAR BRAKE PRESSURE Rear brake pressure: 5,984 ± 589 kPa (61 ± 6 kgf/cm2, 869±86 psi) HINT: The brake pedal should not be depressed twice and/or returned while setting to the specified pressure. Read the value of rear pressure 2 seconds after adjusting the specified fluid pressure. 4. (a) (b) A R05477 IF NECESSARY, ADJUST FLUID PRESSURE Disconnect the No.2 shackle from the shackle bracket. Adjust the length of the No.2 shackle turning it. Low pressure − Lengthen A. High pressure − Shorten A Initial set: 90 mm (3.54 in.) Adjusting range: 84 − 96 mm (3.31 − 3.78 in.) HINT: One turn of the No.2 shackle changes the fluid pressure by about 98.1 kPa (1.0 kgf/cm2, 14.2 psi). (c) In event the pressure cannot be adjusted by No.2 shackle, raise or lower the valve body. Low pressure − Lower High pressure − Raise (d) Torque the 2 nuts. Torque: 13 N·m (130 kgf·cm, 9 ft·lbf) (e) Adjust the length of the No.2 shackle again. If it cannot be adjusted, inspect the valve housing. 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 1027 Brought to you by BirfMark BR−46 BRAKE − LOAD SENSING PROPORTIONING AND BY−PASS VALVE (LSP & BV) 5. IF NECESSARY, CHECK VALVE BODY (a) Assemble the valve body in the uppermost position. HINT: When the brakes are applied, the piston will move down about 1 mm (0.039 in.). Even at this time, the piston should not make contact with or move the load sensing spring. (b) In this position, check the rear brake pressure. Front brake pressure kPa (kgf/cm2, psi) Rear brake pressure kPa (kgf/cm2, psi) 3,434 (35, 498) 3,434 (35, 498) 5,396 (55, 783) 3,630 − 4,218 (37 − 43, 527 − 612) 9,810 (100, 1,424) 4,513 − 5,494 (46 − 56, 655 − 797) 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 1028 Brought to you by BirfMark BRAKE − LOAD SENSING PROPORTIONING AND BY−PASS VALVE (LSP & BV) BR−47 LOAD SENSING PROPORTIONING AND BY−PASS VALVE (LSP & BV) BR1DB−01 COMPONENTS 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BR−48 BRAKE − LOAD SENSING PROPORTIONING AND BY−PASS VALVE (LSP & BV) REMOVAL 1. (a) (b) (c) BR1DD−01 DISCONNECT SHACKLE NO.2 FROM BRACKET Remove the cotter pin. Remove the nut and disconnect the shackle No.2 from the bracket. Remove the retainer, 2 cushions and collar. 2. (a) REMOVE LSP & BV ASSEMBLY Using SST, disconnect the 3 brake lines from the valve body. SST 09751−36011 (b) Remove the valve bracket and 4 mounting bolts, then remove the LSP & BV assembly. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BRAKE − LOAD SENSING PROPORTIONING AND BY−PASS VALVE (LSP & BV) DISASSEMBLY 1. (a) (b) BR−49 BR1DE−01 REMOVE VALVE BRACKET Remove the nut, bolt and 2 plate washers. Remove the 2 nuts, bracket and set plate from the valve body. 2. DISCONNECT SPRING FROM VALVE Using pliers, remove the clip, and remove the spring from the valve. 3. (a) (b) REMOVE SHACKLE NO.1 AND NO.2 Remove the bolt and nut, then remove the these parts: S Load sensing spring S 2 plate washers Loosen the 2 nuts, and remove the shackle No.1 from the shackle No.2. 4. DISASSEMBLE LOAD SENSING SPRING Disassembly the these parts: S 4 bushings S 2 collars S 2 rubber plates S Load sensing valve boot S Load sensing spring boot 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BR−50 BRAKE − LOAD SENSING PROPORTIONING AND BY−PASS VALVE (LSP & BV) INSPECTION BR1DF−01 INSPECT VALVE PISTON PIN AND LOAD SENSING SPRING CONTACT SURFACE FOR WEAR Wear limit: 0.7 mm (0.028 in.) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BRAKE − LOAD SENSING PROPORTIONING AND BY−PASS VALVE (LSP & BV) REASSEMBLY 1. S S S S S BR0070 BR−51 BR1DG−01 ASSEMBLE THESE PARTS TO LOAD SENSING SPRING: Load sensing valve boot Load sensing spring boot 4 bushings 2 rubber plates 2 collars HINT: Apply lithium soap base glycol grease to the parts indicated by the arrrows. Do not mistake the valve side for the shackle side of the load sensing spring. 2. INSTALL SHACKLE NO.1 AND NO.2 TO LOAD SENSING SPRING (a) Install the lock nut and shackle No. 1 to the shackle No. 2. (b) Torque the bolt and nut through the 2 plate washers. Torque: 18 N·m (185 kgf·cm, 13 ft·lbf) 3. INSTALL LOAD SENSING SPRING TO VALVE BODY Install the load sensing spring assembly to the load sensing valve with the clip. 4. INSTALL VALVE BRACKET (a) Install the set plate to the valve assembly through the valve bracket and temporarily tighten the 2 valve body mounting nuts. (b) Torque the bolt and nut through the 2 plate washers. Torque: 18 N·m (185 kgf·cm, 13 ft·lbf) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BR−52 BRAKE − LOAD SENSING PROPORTIONING AND BY−PASS VALVE (LSP & BV) INSTALLATION BR1DH−01 1. INSTALL LSP & BV ASSEMBLY Install the LSP & BV assembly to the frame with the 4 bolts. Torque: 25 N·m (260 kgf·cm, 19 ft·lbf) 2. (a) (b) A (c) (d) R05477 (e) CONNECT SHACKLE NO.2 TO BRACKET Set the dimension A by turning shackle No.2. Initial set: 90 mm (3.54 in.) Tighten the lock nut. Torque: 25 N·m (250 kgf·cm, 18 ft·lbf) Install the 2 bushings and collar to the load sensing spring shackle. Install the load sensing spring shackle to the shackle bracket with a retainer and nut. Torque: 13 N·m (130 kgf·cm, 9 ft·lbf) Install a new cotter pin. 3. CONNECT BRAKE LINES Using SST, connect the 3 brake lines. SST 09751−36011 Torque: 15 N·m (155 kgf·cm, 11 ft·lbf) 4. SET REAR AXLE LOAD (See page BR−45) 5. SET VALVE BODY (a) When pulling down the load sensing spring, confirm that the valve piston moves down smoothly. (b) Position the valve body so that the valve piston lightly contacts the load sensing spring. (c) Tighten the 2 valve body mounting nuts. Torque: 13 N·m (130 kgf·cm, 9 ft·lbf) 6. BLEED BRAKE SYSTEM (See page BR−4) 7. CHECK FLUID LEAKAGE 8. CHECK AND ADJUST LSP & BV FLUID PRESSURE (See page BR−45) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BR−53 BRAKE − ABS ACTUATOR ABS ACTUATOR ON−VEHICLE INSPECTION 1. 2. (a) (b) (c) 3. (a) (b) BR1DI−01 INSPECT BATTERY POSITIVE VOLTAGE Battery positive voltage: 10 − 14 V DISCONNECT CONNECTORS Disconnect the connector from the actuator. Remove the control relay from the actuator bracket. Disconnect the 2 connectors from the control relay. CONNECT ACTUATOR CHECKER (SST) TO ACTUATOR Connect the actuator checker (SST) to the actuator, control relay and body side wire harness through the sub− wire harness C (SST) and E (SST), as shown. SST 09990−00150, 09990−00200, 09990−00210 Connect the red cable of the checker to the battery positive (+) terminal and black cable to the negative (−) terminal. Connect the black cable of the sub−wire harness to the battery negative (−) terminal or body ground. 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 1035 Brought to you by BirfMark BR−54 BRAKE 4. (a) (b) (c) (d) − ABS ACTUATOR INSPECT BRAKE ACTUATOR OPERATION Start the engine, and run it at idle. Turn the selector switch of the actuator checker to ”FRONT RH” position. Push and hold in the SUB MOTOR switch for a few seconds. Depress the brake pedal and hold it until the step (g) is completed. BR1334 (e) Push the POWER switch, and check that the brake pedal does not go down. NOTICE: Do not keep the POWER switch pushed down for more than 10 seconds. (f) Release the switch, and check that the pedal goes down. (g) (h) (i) (j) (k) Push and hold in the SUB MOTOR switch for a few seconds, and check that the pedal returns. Release the brake pedal. Push and hold in the SUB MOTOR switch for a few seconds. Depress the brake pedal and hold it for about 15 seconds. As you hold the pedal down, push the SUB MOTOR switch for a few seconds. Check that the brake pedal does not pulsate. Release the brake pedal. R00326 5. (a) (b) (c) 6. (a) (b) INSPECT FOR OTHER WHEELS Turn the selector switch to ”FRONT LH” position. Repeating (c) to (j) of the step 4, check the actuator operation similarly. Similarly, inspect ”REAR” position. PUSH SUB MOTOR SWITCH Push and hold in the SUB MOTOR switch for a few seconds. Stop the engine. 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 1036 Brought to you by BirfMark BR−55 BRAKE − ABS ACTUATOR 7. BR1334 DISCONNECT ACTUATOR CHECKER (SST) FROM ACTUATOR Disconnect the actuator checker (SST) and sub−wire harness (SST) from the actuator, control relay and body side wire harness. SST 09990−00150, 09990−00200, 09990−00210 8. CONNECT CONNECTORS (a) Connect the 2 connectors to the control relay. (b) Connect the connector to the actuator. (c) Install the control relay to the actuator bracket. 9. CLEAR DTC (See page DI−190) 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 1037 Brought to you by BirfMark BR−56 BRAKE − ABS ACTUATOR BR1DJ−01 COMPONENTS 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BR−57 BRAKE − ABS ACTUATOR REMOVAL 1. BR1DK−01 REMOVE CONTROL RELAY FROM ACTUATOR BRACKET Torque: 13 N·m (130 kgf·cm, 9 ft·lbf) 2. DISCONNECT BRAKE LINES Using SST, disconnect the brake lines from the ABS actuator. SST 09023−00100 Torque: 15 N·m (155 kgf·cm, 11 ft·lbf) 3. REMOVE ABS ACTUATOR ASSEMBLY (a) Disconnect the 2 connectors from the actuator. (b) Remove the 4 bolts and actuator assembly. Torque: 19 N·m (195 kgf·cm, 14 ft·lbf) 4. REMOVE ABS ACTUATOR (a) Remove the 3 nuts and actuator from the actuator bracket. Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf) (b) Remove the 3 holders and cushions from the ABS actuator. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BR−58 BRAKE − ABS ACTUATOR INSPECTION BR1NS−01 1. INSPECT CONTINUITY OF MOTOR RELAY CIRCUIT (a) Check there is continuity between terminals 9 and 10. (b) Check there is no continuity between terminals 7 and 8. If continuity is not as specified, replace the relay. 2. (a) INSPECT OPERATION OF MOTOR RELAY CIRCUIT Connect the positive (+) lead from the battery to terminal 10 and negative (−) lead to terminal 9. (b) Check there is continuity between terminals 7 and 8. If operation is not as specified, replace the relay. 3. (a) (b) INSPECT CONTINUITY OD SOLENOID RELAY CIRCUIT Check there is continuity between terminals 1 and 9. Check there is no continuity between terminals 2 and 5. (c) Connect the positive lead from the ohmmeter to terminal 5 and connect negative lead to terminal 4. (d) Check there is continuity between terminals. (e) Connect the 2 leads in reverse, and check that there is no continuity between terminals. If continuity is not as specified, replace the relay. HINT: For the different type ohmmeter, there is no continuity for step (d), and there is continuity for step (e). 4. INSPECT OPERATION OF SOLENOID RELAY CIRCUIT (a) Connect the positive (+) lead from the battery to terminal 1 and negative (−) lead to terminal 9. (b) Check there is continuity between terminal 2 and 6. (c) Check there is no continuity between terminals 2 and 6. If operation is not as specified, replace the relay. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BR−59 BRAKE − ABS ACTUATOR BR1DL−01 INSTALLATION Installation is in the reverse order of removal (See page BR−57). HINT: After installation, fill the brake reservoir with brake fluid, bleed brake system (see page BR−4) and check for leaks. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BR−60 BRAKE − FRONT SPEED SENSOR FRONT SPEED SENSOR BR1DM−02 COMPONENTS 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 1042 Brought to you by BirfMark BR−61 BRAKE − FRONT SPEED SENSOR REMOVAL BR1DN−02 HINT: When replacing the sensor or sensor harness, replace the sensor and sensor harness together as a set. 1. DISCONNECT SPEED SENSOR CONNECTOR 2. REMOVE SPEED SENSOR (a) Remove the 8 clamp bolts holding the sensor harness from the axle housing. (b) Remove the bolt and wire tie holding the sensor harness from the stabilizer bar. (c) Remove the bolt and 2 clips holding the sensor harness from the frame and body. (d) Remove the 2 installation bolts and speed sensors from the steering knuckle. Torque: 18 N·m (185 kgf·cm, 13 ft·lbf) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BR−62 BRAKE − FRONT SPEED SENSOR INSPECTION 1. (a) BR1NR−01 INSPECT SPEED SENSOR Disconnect the speed sensor connector. R05035 (b) Measure the resistance between terminals FR+ and FR−, and FL+ and FL−. Resistance: 0.5 − 1.6 kΩ If resistance value is not specified, replace the sensor. Z04921 (c) Check there is no continuity between each terminal and sensor body. If there is continuity, replace the sensor. (d) Connect the speed sensor connector. W00552 2. INSPECT SENSOR INSTALLATION Check the sensor installation bolt is tightened properly and there is no clearance between the sensor and axle end. If not, tighten the bolt. Torque: 18 N·m (185 kgf·cm, 13 ft·lbf) R13587 3. (a) (b) VISUALLY INSPECT SENSOR ROTOR SERRATIONS Remove the axle hub with disc (See page SA−67). Inspect the sensor rotor serrations for scratches, cracks, warping or missing teeth. (c) Install the axle hub with disc SA−9). NOTICE: To prevent damage to the serrations, do not strike the axle hub. R04759 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BR−63 BRAKE 4. 5. − FRONT SPEED SENSOR CHECK THAT THERE IS NO FOREIGN OBJECT ON SENSOR CHECK SPEED SENSOR SIGNAL (See page DI−210) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BR−64 BRAKE − FRONT SPEED SENSOR BR1DO−01 INSTALLATION Installation is in the reverse order of removal (See page BR−61). HINT: After installation, check the speed sensor signal (See page DI−190). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BR−65 BRAKE − REAR SPEED SENSOR REAR SPEED SENSOR BR1DP−02 COMPONENTS 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 1047 Brought to you by BirfMark BR−66 BRAKE − REAR SPEED SENSOR REMOVAL BR1DQ−02 HINT: When replacing the sensor or sensor harness, replace the sensor and sensor harness together as a set. 1. DISCONNECT SPEED SENSOR CONNECTOR (a) Disconnect the speed sensor connector. (b) Remove the 3 clamp bolts and 2 clips holding the sensor wire harness from the suspension arm and frame. 2. REMOVE SPEED SENSOR Remove the installation bolt and speed sensor from the axle end. Torque: 18 N·m (185 kgf·cm, 13 ft·lbf) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BR−67 BRAKE − REAR SPEED SENSOR INSPECTION 1. (a) BR1NO−01 INSPECT SPEED SENSOR Disconnect the speed sensor connector. (b) Measure the resistance between terminals. Resistance: 0.5 − 1.6 kΩ If resistance value is not specified, replace the sensor. (c) Check there is no continuity between each terminal and sensor body. If there is continuity, replace the sensor. (d) Connect the speed sensor connector. 2. INSPECT SENSOR INSTALLATION Check the sensor installation bolt is tightened properly and there is no clearance between the sensor and axle end. If not, tighten the bolt. Torque: 18 N·m (185 kgf·cm, 13 ft·lbf) 3. (a) (b) VISUALLY INSPECT SENSOR ROTOR SERRATIONS Remove the brake disc (See page BR−40). Inspect the sensor rotor serrations for scratches, cracks, warping or missing teeth. (c) Install the brake disc. NOTICE: To prevent damage to the serrations, do not strike the axle hub. R04775 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BR−68 BRAKE 4. 5. − REAR SPEED SENSOR CHECK THAT THERE IS NO FOREIGN OBJECT ON SENSOR CHECK SPEED SENSOR SIGNAL (See page DI−210) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark BR−69 BRAKE − REAR SPEED SENSOR BR1DR−01 INSTALLATION Installation is in the reverse order of removal (See page BR−66). HINT: After installation, check the speed sensor signal (see page DI−190). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark CH−1 CHARGING − CHARGING SYSTEM CH0HN−01 PRECAUTION CAUTION: S Check that the battery cables are connected to the correct terminals. S Disconnect the battery cables when the battery is given a quick charge. S Do not perform tests with a high voltage insulation resistance tester. S Never disconnect the battery while the engine is running. 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 766 Brought to you by BirfMark CH−2 CHARGING − CHARGING SYSTEM CHARGING SYSTEM ON−VEHICLE INSPECTION CH0EO−02 1. CHECK BATTERY ELECTROLYTE LEVEL AND VOLTAGE (a) Check the electrolyte quantity of each cell. If under the lower level, replace the battery (or add distilled water if possible). check the charging system. (b) Measure the battery voltage between the negative (−) and positive (+) terminals of the battery. Standard voltage: At 20°C (68°F): 12.7 − 12.9 V HINT: Before measuring the voltage, turn the ignition switch OFF and turn off the electrical systems (headlight, blower motor, rear defogger etc.). S If the vehicle has been running, wait 20 minutes or more after the vehicle stops before measuring the battery voltage. If the voltage is less than specification, charge the battery. S Blue OK White Charging Necessary HINT: Check the indicator as shown in the illustration. Red Add Distilled Water CH0712 2. (a) CHECK BATTERY TERMINALS, FUSIBLE LINK AND FUSES Check that the battery terminals are not loose or corroded. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark CH−3 CHARGING (b) − CHARGING SYSTEM Check the fusible link and fuses for continuity. MAIN 2.0 A AM1 1.25 B Fusible link AM2 0.3 P H−fuse AM1 50 A IGN 7.5 A Fuse CORRECT GAUGE 15 A 3. (a) INSPECT DRIVE BELTS 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 belts as a set. WRONG Clearance P03788 Nippondenso Borroughs (b) Using a belt tension gauge, measure the belt tension. Belt tension gauge: Nippondenso BTG−20 (95506−00020) Borroughts No. BT−33−73F Drive belt tension: Z00038 New belt 400 − 580 N (41.0 − 59.1 kgf, 90.4 − 130.2 lbf) Used belt 200 − 390 N (20.4 − 40.0 kgf, 45.0 − 88.2 lbf) If the belt tension is not as specified, adjust it. HINT: S ”New belt” refers to a belt which has been used less than 5 minutes on a running engine. S ”Used belt” refers to a belt which has been used on a running engine for 5 minutes or more. S After installing a new belt, run the engine for about 5 minutes and recheck the belt tension. 4. (a) (b) 5. (a) (b) VISUALLY CHECK GENERATOR WIRING AND LISTEN FOR ABNORMAL NOISES Check that the wiring is in good condition. Check that there is no abnormal noise from the generator while the engine is running. INSPECT DISCHARGE WARNING LIGHT CIRCUIT Turn the ignition switch ”ON”. Check that the discharge warning light comes on. Start the engine. Check that the light goes off. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark CH−4 CHARGING − CHARGING SYSTEM If the light does not operate as specified, troubleshoot the discharge warning light circuit. 6. INSPECT CHARGING CIRCUIT WITHOUT LOAD HINT: If a battery/generator tester is available, connect the tester to the charging circuit as per the manufacturer’s instructions. (a) If a tester is not available, connect a voltmeter and ammeter to the charging circuit as follows: S Disconnect the wire from terminal B of the generator and connect it to the negative (−) lead of the ammeter. S Connect the positive (+) lead of the ammeter to terminal B of the generator. S Connect the positive (+) lead of the voltmeter to terminal B of the generator. S Ground the negative (−) lead of the voltmeter. (b) Check the charging circuit as follows: With the engine running from idle to 2,000 rpm, check the reading on the ammeter and voltmeter. Standard amperage 10 A or less Standard voltage: at 25°C ’(77°F) 14.0 − 15.0 V at 115°C ’(239°F) 13.5 − 14.3 V If the voltmeter reading is more than standard voltage, replace the voltage regulator. If the voltmeter reading is less than the standard voltage, check the voltage regulator and generator as follows: With terminal F grounded, start the engine and check the voltmeter reading of terminal B. S If the voltmeter reading is more than standard voltage, replace the voltage regulator. S If the voltmeter reading is less than standard voltage, check the generator. INSPECT CHARGING CIRCUIT WITH LOAD With the engine running at 2,000 rpm, turn on the high beam headlights and place the heater blower switch at ”HI”. S 7. (a) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark CH−5 CHARGING − CHARGING SYSTEM (b) Check the reading on the ammeter. Standard amperage: 30 A or more If the ammeter reading is less than standard amperage, repair the generator. HINT: If the battery is fully charged, the indication will sometimes be less than standard amperage. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark CH−6 CHARGING − GENERATOR GENERATOR CH06H−05 COMPONENTS 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 771 Brought to you by BirfMark CH−7 CHARGING − GENERATOR 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 772 Brought to you by BirfMark CH−8 CHARGING − GENERATOR REMOVAL 1. 2. 3. (a) (b) 4. (a) (b) (c) (d) (e) CH0EP−01 REMOVE BATTERY AND BATTERY TRAY DISCONNECT POWER STEERING (PS) RESERVOIR TANK REMOVE DRIVE BELTS Loosen the lock bolt, pivot bolt and adjusting bolt. Remove the 2 drive belts. REMOVE GENERATOR Disconnect the generator connector. Remove the rubber cap and nut, and disconnect the generator wire. Disconnect the generator wire clamp from the generator. Remove the lock bolt, bolt, nut and drive belt adjusting bar. Remove the pivot bolt and generator. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark CH−9 CHARGING − GENERATOR DISASSEMBLY CH0HO−01 1. (a) REMOVE REAR END COVER Remove the nut and terminal insulator. (b) Remove the 3 nuts, bolt, rectifier plate and rear end cover. 2. (a) REMOVE BRUSH HOLDER Remove the brush holder cover from the brush holder. (b) Remove the 2 screws and brush holder. 3. REMOVE VOLTAGE REGULATOR Remove the 3 screws and voltage regulator. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark CH−10 CHARGING SST (B) SST (A) GENERATOR 4. (a) REMOVE RECTIFIER HOLDER Remove the 4 screws and rectifier holder. (b) Remove the 4 rubber insulators. (c) Remove the seal plate. 5. (a) (b) REMOVE PULLEY Hold SST (A) with a torque wrench, and tighten SST (B) clockwise to the specified torque. SST 09820−63010 Torque: 39 N·m (400 kgf·cm, 29 ft·lbf) Check that SST (A) is secured to the rotor shaft. (c) (d) Mount SST (C) in a vise. Install the generator to SST (C). Turn Hold − P03807 SST (C) P08242 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark CH−11 CHARGING − GENERATOR (e) To loosen the pulley nut, turn SST (A) in the direction shown in the illustration. NOTICE: To prevent damage to the rotor shaft, do not loosen the pulley nut more than one−half of a turn. (f) Remove the generator from SST (C). (g) Turn SST (B) and remove SST (A and B). (h) Remove the pulley nut and pulley. SST (C) SST (A) Turn P08243 6. (a) REMOVE RECTIFIER END FRAME Remove the 4 nuts. (b) Using SST, remove the rectifier end frame. SST 09286−46011 (c) Remove the generator washer. 7. REMOVE ROTOR FROM DRIVE END FRAME P03794 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark CH−12 CHARGING − GENERATOR INSPECTION CH0HP−01 1. INSPECT ROTOR FOR OPEN CIRCUIT Using an ohmmeter, check that there is continuity between the slip rings. Standard resistance (At 20°C (68°F): 2.8 − 3.0 Ω If there is no continuity, replace the rotor. Ohmmeter Continuity CH0784 2. INSPECT ROTOR FOR GROUND Using an ohmmeter, check that there is no continuity between the slip ring and rotor. If there is continuity, replace the rotor. Ohmmeter No Continuity CH0783 3. INSPECT SLIP RINGS (a) Check that the slip rings are not rough or scored. If rough or scored, replace the rotor. (b) Using a vernier caliper, measure the slip ring diameter. Standard diameter: 14.2 − 14.4 mm (0.559 − 0.567 in.) Minimum diameter: 12.8 mm (0.504 in.) If the diameter is less than minimum, replace the rotor. CH0192 4. INSPECT STATOR FOR OPEN CIRCUIT Using an ohmmeter, check that there is continuity between the coil leads. If there is no continuity, replace the drive end frame assembly. Continuity Ohmmeter P00484 5. INSPECT STATOR FOR GROUND Using an ohmmeter, check that there is no continuity between the coil lead and drive end frame. If there is continuity, replace the drive end frame assembly. No Continuity Ohmmeter P00482 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark CH−13 CHARGING − GENERATOR 6. INSPECT EXPOSED BRUSH LENGTH Using vernier calipers, measure the exposed brush length. Standard exposed length: 10.5 mm (0.413 in.) Minimum exposed length: 1.5 mm (0.059 in.) If the exposed length is less than minimum, replace the brushes and brush holder assembly. Length P13535 7. (a) INSPECT POSITIVE RECTIFIER Using an ohmmeter, connect one tester probe to the positive (+) 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 and the other shows no continuity. If continuity is not as specified, replace the rectifier holder. Positive (+) Terminal Rectifier Ohmmeter Terminal Z04143 8. (a) Negative (−) Terminal Ohmmeter Z04144 INSPECT NEGATIVE RECTIFIER Using an ohmmeter, connect one tester probe to each 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 and the other shows no continuity. If continuity is not as specified, replace the rectifier holder. 9. INSPECT FRONT BEARING Check that the bearing is not rough or worn. P00644 10. INSPECT REAR BEARING Check that the bearing is not rough or worn. CH1026 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark CH−14 CHARGING − GENERATOR REPLACEMENT CH0HQ−01 1. (a) REPLACE FRONT BEARING Remove the 4 screws and bearing retainer. (b) Using SST and a press, press out the bearing. SST 09950−60010 (09951−00260, 09952−06010) (c) Using SST and a press, press in a new bearing. SST 09950−60010 (09951−00500) (d) Install the bearing retainer with the 4 screws. Torque: 2.6 N·m (27 kgf·cm, 23 in.·lbf) SST P22368 SST P22369 2. (a) REPLACE REAR BEARING Using SST, remove the bearing cover (outside) and bearing. SST 09820−00021 NOTICE: Be careful not to damage the fan. (b) Remove the bearing cover (inside). SST N00581 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark CH−15 CHARGING Bearring Cover − GENERATOR (c) Place the bearing cover (inside) on the rotor. (d) Using SST and a press, press in a new bearing. SST 09820−00030 (e) Using SST, push in the bearing cover (outside). SST 09285−76010 P05052 SST N00578 SST P00074 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark CH−16 CHARGING − GENERATOR REASSEMBLY CH06M−03 1. 2. PLACE RECTIFIER END FRAME ON PULLEY INSTALL ROTOR TO DRIVE END FRAME 3. (a) INSTALL RECTIFIER END FRAME Place the generator washer on the rotor. (b) Using a 29 mm socket wrench and press, slowly press in the rectifier end frame. Install the 4 nuts. Torque: 4.5 N·m (46 kgf·cm, 40 in.·lbf) P03802 P03794 (c) SST (A) SST (B) 4. (a) (c) INSTALL PULLEY Install the pulley to the rotor shaft by tightening the pulley nut by hand. Hold SST (A) with a torque wrench, and tighten SST (B) clockwise to the specified torque. SST 09820−63010 Torque: 39 N·m (400 kgf·cm, 29 ft·lbf) Check that SST (A) is secured to the pulley shaft. (d) (e) Mount SST (C) in a vise. Install the generator to SST (C). (b) Turn Hold P03807 SST (C) P08242 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark CH−17 CHARGING (f) SST (A) GENERATOR (g) (h) To torque the pulley nut turn SST (A) in the direction shown in the illustration. Torque: 110.5 N·m (1,128 kgf·cm, 81 ft·lbf) Remove the generator from SST (C). Turn SST (B), and remove SST (A and B). 5. (a) INSTALL RECTIFIER HOLDER Place the seal plate on the rectifier end frame. (b) Install the 4 rubber insulators on the lead wires. (c) Install the rectifier holder with the 4 screws. Torque: 2.9 N·m (30 kgf·cm, 25 in.·lbf) SST (C) Turn − P08244 6. INSTALL VOLTAGE REGULATOR Install the voltage regulator on the rectifier end frame with the 3 screws. Torque: 2.0 N·m (20 kgf·cm, 17 in.·lbf) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark CH−18 CHARGING − GENERATOR 7. (a) INSTALL BRUSH HOLDER Install the brush holder on the rectifier end frame with the 2 screws. NOTICE: Be careful of the holder installation direction. Torque: 2.0 N·m (20 kgf·cm, 17 in.·lbf) (b) Place the brush holder cover on the brush holder. 8. (a) INSTALL REAR END COVER Install the end cover together with the rectifier plate. (1) Hand tighten the bolt first for positioning the plate. (2) Tighten the 3 nuts and bolt. Torque: Bolt: 3.8 N·m (39 kgf·cm, 34 in.·lbf) Nut: 4.4 N·m (45 kgf·cm, 39 in.·lbf) (b) Install the terminal insulator with the nut. Torque: 4.1 N·m (42 kgf·cm, 36 in.·lbf) CHECK THAT ROTOR ROTATES SMOOTHLY 9. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark CH−19 CHARGING − GENERATOR INSTALLATION 1. (a) (b) (c) (d) (e) (f) 2. (a) (b) (c) 3. 4. 5. CH06N−03 INSTALL GENERATOR Mount generator on the generator bracket with the pivot bolt. Do not tighten the bolt yet. Install the drive belt adjusting bar with the bolt and nut. Torque: 21 N·m (210 kgf·cm, 15 ft·lbf) Temporarily install the lock bolt. Connect the generator connector. Connect the generator wire with the nut and rubber cap. Connect the generator wire clamp to the generator. INSTALL DRIVE BELTS Install the drive belts. Adjust the drive belt with the adjusting bolt (See page CH−2). Tighten the pivot and adjusting lock bolts. Torque: Pivot bolt: 59 N·m (600 kgf·cm, 43 ft·lbf) Lock bolt: 21 N·m (210 kgf·cm, 15 ft·lbf) CONNECT POWER STEERING (PS) RESERVOIR TANK INSTALL BATTERY TRAY AND BATTERY PERFORM ON−VEHICLE INSPECTION (See page CH−2) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark CO−1 COOLING − COOLANT COOLANT CO0IO−04 INSPECTION HINT: Check the coolant level when the engine is cold. 1. CHECK ENGINE COOLANT LEVEL AT RADIATOR RESERVOIR The engine coolant level should be between the ”LOW” and ”FULL” lines. If low, check for leaks and add engine coolant up to the ”FULL” line. 2. CHECK ENGINE COOLANT QUALITY (a) Remove the radiator cap. CAUTION: To avoid the danger of being burned, do not remove the radiator cap while the engine and radiator are still hot, as fluid and steam can be blown out under pressure. (b) There should not be any excessive deposits of rust or scale around the radiator cap or radiator filler hole, and the coolant should be free from oil. If excessively dirty, replace the coolant. (c) Reinstall the radiator cap. 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 696 Brought to you by BirfMark CO−2 COOLING − COOLANT REPLACEMENT CO0IP−07 REPLACE ENGINE COOLANT (a) Remove the radiator cap. CAUTION: See step 2. (a) above. (b) Drain the coolant from the radiator drain cock and engine drain plug (Engine drain plug at the left of engine block.). (c) Close the drain plugs. Torque:Torque (Engine drain plug): 29 N·m (300 kgf·cm, 22 ft·lbf) (d) Slowly fill the system with coolant. S Use a good brand of ethylene−glycol base coolant and mix it according to the manufacturer’s directions. S Using coolant which includes more than 50 % ethylene−glycol (but not more than 70 %) is recommended. NOTICE: Do not use an alcohol type coolant.The coolant should be mixed with demineralized water or distilled water. Capacity: w/ Front heater: 13.7 liters (14.4 US qts, 12.1 lmp. qts) w/ Front and rear heaters: 14.7 liters (15.5 US qts, 12.9 lmp. qts) (e) Reinstall the radiator cap. (f) Warm up the engine and check for leaks. (g) Recheck the coolant level and refill as necessary. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark CO−3 COOLING − WATER PUMP WATER PUMP CO111−01 COMPONENTS 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 698 Brought to you by BirfMark CO−4 COOLING − WATER PUMP REMOVAL CO112−01 1. 2. 3. DRAIN ENGINE COOLANT DISCONNECT NO.3 WATER BYPASS HOSE DISCONNECT RADIATOR INLET HOSE 4. REMOVE DRIVE BELTS, FAN WITH FLUID COUPLING, WATER PUMP PULLEY AND FAN SHROUD Stretch the belts and loosen the water pump pulley mounting nuts. (a) (b) Loosen the lock, pivot and adjusting bolts of the generator, and remove the drive belts. (c) Disconnect the oil cooler hose from the clamp on the fan shroud. (d) Remove the 2 bolts holding the fan shroud to the radiator. (e) Remove the 4 water pump pulley mounting nuts. (f) Pull out the fan with fluid coupling, water pump pulley and fan shroud. (g) Remove the fan from the fluid coupling. 5. REMOVE WATER PUMP Remove the 4 bolts, 2 nuts, water pump and gasket. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark CO−5 COOLING − WATER PUMP INSPECTION CO113−04 1. (a) INSPECT WATER PUMP Visually check the air hole and water hole for coolant leakage. If leakage is found, replace the water pump. (b) Turn the pulley seat and check that the water pump bearing moves smoothly and quietly. If necessary, replace the water pump. 2. INSPECT FLUID COUPLING Check the fluid coupling for damage and silicon oil leakage. If necessary, replace the fluid coupling. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark CO−6 COOLING − WATER PUMP INSTALLATION CO114−02 1. INSTALL WATER PUMP Install a new gasket and the water pump with the 4 bolts and 2 nuts. Torque: 21 N·m (210 kgf·cm, 15 ft·lbf) 2. INSTALL WATER PUMP PULLEY, FAN SHROUD, FAN WITH FLUID COUPLING AND DRIVE BELTS (a) Install fan to the fluid coupling. (b) (c) (d) (e) (f) (g) (h) 3. 4. 5. 6. Place the fan with fluid coupling, water pump pulley and fan shroud in position. Temporarily install the fan pulley mounting nuts. Install the fan shroud with the 2 bolts. Torque: 5.0 N·m (50 kgf·cm, 43 in.·lbf) Connect the oil cooler hose to the clamp on the fan shroud. Install the drive belts with the adjusting bolt and pivot bolt. Stretch the belts tight and tighten the 4 water pump pulley mounting nuts. Adjust the drive belts (See page CH−2). CONNECT NO.3 WATER BYPASS HOSE CONNECT RADIATOR INLET HOSE FILL RADIATOR WITH ENGINE COOLANT START ENGINE AND CHECK FOR LEAKS 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark CO−7 COOLING − THERMOSTAT THERMOSTAT CO0IU−03 COMPONENTS 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 702 Brought to you by BirfMark CO−8 COOLING − THERMOSTAT CO115−01 REMOVAL HINT: Removal of the thermostat would have an adverse effect, causing a lowering of cooling efficiency. Do not remove the thermostat, even if the engine tends to overheat. 1. DRAIN ENGINE COOLANT 2. REMOVE WATER INLET AND THERMOSTAT 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark CO−9 COOLING − THERMOSTAT INSPECTION CO0IW−06 INSPECT THERMOSTAT HINT: 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: 80 − 84°C (176 − 183°F) If the valve opening temperature is not as specified, replace the thermostat. (c) Check the valve lift. Valve lift: 10 mm (0.39 in.) or more at 95°C (203°F) If the valve lift is not as specified, replace the thermostat. (d) Check that the valve is fully closed when the thermostat is at low temperatures (below 40°C (104°F)). If not closed, replace the thermostat. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark CO−10 COOLING − THERMOSTAT INSTALLATION 1. (a) (b) CO116−01 PLACE THERMOSTAT IN WATER PUMP Install a new gasket on to the thermostat. Align the thermostat jiggle valve with the protrusion of the water inlet housing, and insert the thermostat in the water inlet housing. HINT: The jiggle valve may be set within 15° of either side of the prescribed position. 2. INSTALL WATER INLET Install the water inlet with the 3 nuts. Torque: 21 N·m (210 kgf·cm, 15 ft·lbf) 3. FILL RADIATOR WITH ENGINE COOLANT 4. START ENGINE AND CHECK FOR LEAKS 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark CO−11 COOLING − RADIATOR RADIATOR CO0IY−02 ON−VEHICLE CLEANING NOTICE: If using a high pressure type cleaner, be careful not to deform the fins of the radiator core. (i.e. Maintain a distance between the cleaner nozzle and radiator core) 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 706 Brought to you by BirfMark CO−12 COOLING − RADIATOR ON−VEHICLE INSPECTION CO0IZ−03 1. REMOVE RADIATOR TANK CAP CAUTION: To avoid the danger of being burned, do not remove the radiator cap while the engine and radiator are still hot, as fluid and steam can be blown out under pressure. Z02362 2. INSPECT RADIATOR CAP NOTICE: If the radiator cap has contaminations, always rinse it with water. Before using a radiator cap tester, wet the relief valve and pressure valve with coolant or water. Using a radiator cap tester, pump the tester and measure the relief valve opening pressure. Standard opening pressure: 74 − 103 kPa (0.75 − 1.05 kgf/cm2, 10.7 − 14.9 psi) Minimum opening pressure: 59 kPa (0.6 kgf/cm2, 8.5 psi) HINT: Use the tester’s maximum reading as the opening pressure. If the opening pressure is less than minimum, replace the radiator cap. 3. (a) INSPECT COOLING SYSTEM FOR LEAKS Fill the radiator with coolant and attach a radiator cap tester. (b) Warm up the engine. (c) Pump it to 118 kPa (1.2 kgf/cm2, 17.1 psi), and check that the pressure does not drop. If the pressure drops, check the hoses, radiator or water pump for leaks. If no external leaks are found, check the heater core, cylinder block and head. 4. REINSTALL RADIATOR CAP 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark CO−13 COOLING − RADIATOR CO0J0−03 COMPONENTS 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark CO−14 COOLING − RADIATOR REMOVAL CO117−02 1. DRAIN ENGINE COOLANT 2. REMOVE BATTERY AND BATTERY TRAY (a) Disconnect the battery cables. (b) Remove the nuts, hold−down clamp and battery. (c) Remove the bolt and disconnect the ground strap. (d) Remove the 5 bolts and battery tray. 3. REMOVE RADIATOR GRILLE Remove the 5 screws, clip and radiator grille. 4. 5. 6. 7. (a) DISCONNECT NO.3 WATER BYPASS HOSE DISCONNECT RADIATOR INLET HOSE DISCONNECT RADIATOR RESERVOIR HOSE REMOVE RADIATOR Stretch the belts and loosen the water pump pulley mounting nuts. (b) Loosen the lock, pivot and adjusting bolts of the generator, and remove the drive belts. (c) Disconnect the oil cooler hose from the clamp on the fan shroud. Remove the 2 bolts holding the fan shroud to the radiator. Remove the 4 water pump pulley mounting nuts. Pull out the fan with fluid coupling, water pump pulley and fan shroud. (d) (e) (f) 8. 9. DISCONNECT A/T OIL COOLER HOSES DISCONNECT RADIATOR OUTLET HOSE 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark CO−15 COOLING − RADIATOR 10. (a) REMOVE RADIATOR Remove the 2 bolts, 2 nuts and radiator. (b) Remove the 4 nuts and 2 radiator brackets. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark CO−16 COOLING − RADIATOR INSTALLATION 1. (a) (b) 2. 3. 4. (a) (b) (c) (d) (e) (f) (g) CO118−01 INSTALL RADIATOR Install the 2 radiator brackets with the 4 nuts. Torque: 12 N·m (120 kgf·cm, 9 ft·lbf) Install the radiator with the 2 bolts and 2 nuts. Torque: Bolt: 18 N·m (185 kgf·cm, 13 ft·lbf) Nut: 12 N·m (120 kgf·cm, 9 ft·lbf) CONNECT A/T OIL COOLER HOSES CONNECT RADIATOR OUTLET HOSE INSTALL WATER PUMP PULLEY, FAN SHROUD, FAN WITH FLUID COUPLING AND DRIVE BELTS Place the fan with fluid coupling, water pump pulley and fan shroud in position. Temporarily install the fan pulley mounting nuts. Install the fan shroud with the 2 bolts. Torque: 5.0 N·m (50 kgf·cm, 43 in.·lbf) Connect the oil cooler hose to the clamp on the fan shroud. Install the drive belts with the adjusting bolt and pivot bolt. Stretch the belts tight and tighten the 4 water pump pulley mounting nuts. Adjust the drive belts (See page CH−2). 5. CONNECT RADIATOR RESERVOIR HOSE 6. CONNECT RADIATOR INLET HOSE 7. CONNECT NO.3 WATER BYPASS HOSE 8. INSTALL RADIATOR GRILLE Install the radiator grille with the 5 screws and clip. 9. (a) (b) (c) (d) 10. 11. 12. INSTALL BATTERY AND BATTERY TRAY Install the battery tray with the 5 bolts. Connect the ground strap with the bolt. Install the battery with the hold−down clamp and nuts. Connect the battery cables. FILL RADIATOR WITH ENGINE COOLANT START ENGINE AND CHECK FOR LEAKS CHECK AUTOMATIC TRANSMISSION FLUID LEVEL 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−1 − DIAGNOSTICS ENGINE ENGINE DI5OS−02 HOW TO PROCEED WITH TROUBLESHOOTING Troubleshoot in accordance with the procedure on the following page. Titles inside are titles of pages in this manual, with the page number indicated in the bottom portion. See the indicated pages for detailes explanations. Vehicle Brought to Workshop 1 2 Customer Problem Analysis P. DI−2 Connect the OBD II scan tool or TOYOTA hand−held tester to DLC3 P. DI−3 If the display indicates a communication fault in the tool, inspect DLC3 P. DI−3 3 Check DTC and Freezed Frame Data (Precheck) Record or Print DTC and Freezed Frame Data P. DI−3 4 Clear DTC and Freezed Frame Data P. DI−3 5 Visual Inspection 6 Setting the Check Mode Diagnosis P. DI−3 7 Problem Symptom Confirmation If the engine does not start, perform steps 10 and 12 first Malfunction occurs. 9 10 DTC Check P. DI−13 Normal Malfunction code. 11 Basic Inspection P. DI−3 12 14 Malfunction does not occur. Symptom Simulation P. IN−18 8 DTC Chart P. DI−13 Matrix Chart of Problem Symptoms P. DI−19 Parts Inspection 15 13 Circuit Inspection P. DI−20 Check for Intermittent Problems P. DI−3 Identification of Problem 16 Adjustment, Repair 17 Confirmation Test End 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 168 Brought to you by BirfMark DI−2 − DIAGNOSTICS ENGINE DI5OT−01 CUSTOMER PROBLEM ANALYSIS CHECK ENGINE CONTROL SYSTEM Check Sheet Inspector’s Name Model and Model Year Driver’s Name Frame No. Data Vehicle Brought in Engine Model License No. Odometer Reading Problem Symptoms Customer’s Name Engine does not Start Engine does not crank Difficult to Start Engine cranks slowly Other Poor Idling Incorrect first idle Idling rpm is abnormal Rough idling Other Poor Driveability Hesitation Knocking Engine Stall Soon after starting After accelerator pedal depressed After accelerator pedal released During A/C operation Shifting from N to D Other km miles No initial combustion Back fire Other No complete combustion High ( rpm) Low ( Muffler explosion (after−fire) Surging Others Datas Problem Occurred Constant Other Condition When Problem Occurs Problem Frequency Sometimes ( times per day/month) Weather Fine Cloudy Rainy Snowy Outdoor Temperature Hot Warm Cool Cold (approx. Place Highway Rough road Engine Temp. Cold Engine Operation Just after starting ( Starting Driving Constant speed A/C switch ON/OFF Other Condition of MIL Normal mode (Precheck) DTC Inspection Check Mode Suburbs Other Warming up Inner City After Warming up Once only Various/Other °F/ Uphill Any temp. min.) Idling Acceleration °C) Downhill Other Racing Deceleration Remains on Sometimes light up Normal Malfunction code(s) (code Freezed frame data ( ) Malfunction code(s) (code Freezed frame data ( ) Normal 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Does not light up ) ) rpm) Brought to you by BirfMark DI−3 DIAGNOSTICS − ENGINE PRE−CHECK DI5OU−02 1. (a) FI0534 TOYOTA−Hand−Held Tester DIAGNOSIS SYSTEM Description S When troubleshooting OBD II vehicles, the only difference from the usual troubleshooting procedure is that you connect to the vehicle the OBD II scan tool complying with SAE J1978 or TOYOTA hand− held tester, and read off various data output from the vehicle’s ECM. S OBD II regulations require that the vehicle’s on− board computer lights up the Malfunction Indicator Lamp (MIL) on the instrument panel when the computer detects a malfunction in the computer itself or in drive system components which affect vehicle emissions. In addition to the MIL lighting up when a malfunction is detected, the applicable Diagnostic Trouble Codes (DTC) prescribed by SAE J2012 are recorded in the ECM memory (See page DI−13). If the malfunction does not reoccur in 3 trips, the MIL goes off but the DTC remain recorded in the ECM memory. S S DLC3 P22892 To check the DTC, connect the OBD II scan tool or TOYOTA hand−held tester to Data Link Connector 3 (DLC3) on the vehicle. The OBD II scan tool or TOYOTA hand−held tester also enables you to erase the DTCs and check freezed frame data and various forms of engine data (For operating instructions, see the OBD II scan tool’s instruction book.). DTC include SAE controlled codes and manufacturer controlled codes. SAE controlled codes must be set as prescribed by the SAE, while manufacturer controlled codes can be set freely by the manufacturer within the prescribed limits (See DTC chart on page DI−13). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−4 DIAGNOSTICS − ENGINE The diagnosis system operates in normal mode during normal vehicle use. It also has a check mode for technicians to simulate malfunction symptoms and troubleshoot. Most DTC use 2 trip detection logic* to prevent erroneous detection, and ensure thorough malfunction detection. By switching the ECM to check mode when troubleshooting, the technician can cause the MIL to light up for a malfunction that is only detected once or momentarily (TOYOTA hand−held tester only) (See step 2). S *2 trip detection logic: When a logic malfunction is first detected, the malfunction is temporarily stored in the ECM memory. If the same malfunction is detected again during the second drive test, this second detection causes the MIL to light up. S The 2 trip repeats the same mode a 2nd time (However, the IG switch must be turned OFF between the 1st trip and 2nd trip.). S Freeze frame data: Freeze frame data records the engine condition when a misfire (DTC P0300 − P0306) or fuel trim malfunction (DTC P0171, P0172) or other malfunction (first malfunction only), is detected. S Because freeze frame data records the engine conditions (fuel system, calculator load, engine coolant temperature, fuel trim, engine speed, vehicle speed, etc.) when the malfunction is detected, when troubleshooting it is useful for determining whether the vehicle was running or stopped, the engine warmed up or not, the air−fuel ratio lean or rich, etc. at the time of the malfunction. Priorities for troubleshooting: If troubleshooting priorities for multiple DTCs are given in the applicable diagnostic chart, these should be followed. If no instructions are given troubleshoot DTCs according to the following priorities. (1) DTC other than fuel trim malfunction (DTC P0171, P0172), EGR (DTC P0401, P0402), and misfire (DTC P0300 − P0306). (2) Fuel trim malfunction (DTC P0171, P0172), and EGR (DTC P0401, P0402). (3) Misfire (DTC P0300 − P0306). (b) Check the DLC3. The vehicle’s ECM uses V.P.W. (Variable Pulse Width) for communication to comply with SAE J1850. The terminal arrangement of DLC3 complies with SAE J1962 and matches the V.P.W. format. S N09214 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−5 DIAGNOSTICS − ENGINE Terminal No. Connection / Voltage or Resistance Condition 2 Bus ę Line / Pulse generation During transmission 4 Chassis Ground / ↔ Body Ground 1 Ω or less Always 5 Signal Ground / ↔ Body Ground 1 Ω or less Always 16 Battery Positive / ↔ Body Ground 9 − 14 V Always HINT: If your display shows ”UNABLE TO CONNECT TO VEHICLE” when you have connected the cable of the OBD II scan tool or TOYOTA hand−held tester to DLC3, turned the ignition switch ON and operated the scan tool, there is a problem on the vehicle side or tool side. S If communication is normal when the tool is connected to another vehicle, inspect DLC3 on the original vehicle. S If communication is still not possible when the tool is connected to another vehicle, the problem is probably in the tool itself, so consult the Service Department listed in the tool’s instruction manual. 2. (a) P22215 INSPECT DIAGNOSIS (NORMAL MODE) Check the MIL. (1) The MIL comes on when the ignition switch is turned ON and the engine is not running. HINT: If the MIL does not light up, troubleshoot the combination meter (See page BE−2). (2) When the engine started, the MIL should go off. If the lamp remains on, the diagnosis system has detected a malfunction or abnormality in the system (b) Check the DTC. NOTICE: TOYOTA hand−held tester only: When the diagnosis system is switched from normal mode to check mode, it erases all DTCs and freezed frame data recorded in normal mode. So before switching modes, always check the DTCs and freezed frame data, and note them down (1) Prepare the OBD II scan tool (complying with SAE J 1978) or TOYOTA hand−held tester. (2) Connect the OBD II scan tool or TOYOTA hand− held tester to DLC3 in the fuse box at the lower left of the instrument panel. (3) Turn the ignition switch ON and switch the OBD II scan tool or TOYOTA hand−held tester switch ON. (4) Use the OBD II scan tool or TOYOTA hand−held tester to check the DTC and freezed frame data, note them down. (For operating instructions, see the OBD II scan tool’s instruction book.) (5) See page DI−13 to confirm the details of the DTCs. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−6 DIAGNOSTICS − ENGINE NOTICE: When simulating symptoms with an OBD II scan tool (excluding TOYOTA hand−held tester) to check the DTC, use normal mode. For codes on the DTC chart subject to ”2 trip detection logic”, turn the ignition switch OFF after the symptom is simulated the first time. Then repeat the simulation process again. When the problem has been simulated twice, the MIL lights up and the DTCs are recorded in the ECM. 3. INSPECT DIAGNOSIS (CHECK MODE) HINT: TOYOTA hand−held tester only: Compared to the normal mode, the check mode has an increased sensitivity to detect malfunctions. Furthermore, the same diagnostic items which are detected in the normal mode can also be detected in the check mode. (a) Check the DTC. (1) Initial conditions S Battery positive voltage 11 V or more. S Throttle valve fully closed. S Transmission in ”park” or ”neutral” position. S Air conditioning switched OFF. (2) Turn ignition switch OFF. (3) Prepare the TOYOTA hand−held tester. (4) Flashing (5) ON (6) OFF (7) 0.13 Second FI3605 (8) Connect the TOYOTA hand−held tester to DLC3 in the fuse box at the lower left of the instrument panel. Turn the ignition switch ON and push the TOYOTA hand−held tester ON. Switch the TOYOTA hand−held tester normal mode to check mode (Check that the MIL flashes.). Switch the engine (The MIL goes out after the engine start.). Simulate the conditions of the malfunction described by the customer. NOTICE: Leave the ignition switch ON until you have checked the DTC, etc. (9) After simulating the malfunction conditions, use the TOYOTA hand−held tester diagnosis selector to check the DTCs and freezed frame data, etc. HINT: Take care not to turn the ignition switch OFF. Turning the ignition switch OFF switches the diagnosis system from check mode to normal mode, so all DTCs, etc. are erased. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−7 DIAGNOSTICS − ENGINE (10) After checking the DTC, inspect the applicable circuit. (b) Clear the DTC. The following actions will erase the DTCs and freezed frame data. (1) Operating the OBD II scan tool (complying with SAE J1978) or TOYOTA hand−held tester to erase the codes. (See the OBD II scan tool’s instruction book for operating instructions.) (2) Disconnecting the battery terminals or EFI fuse. NOTICE: If the TOYOTA hand−held tester switches the ECM from normal mode to check mode or vice−versa, or if the ignition switch is turned from ON to ACC or LOCK during check mode, the DTCs and freezed frame data will be erased. 4. FAIL−SAFE CHART If any of the following codes is recorded, the ECM enters fail−safe mode. DTC No. Fail−Safe Operation Fail−Safe Deactivation Conditions P0100 S Ignition timing fixed at 5° BTDC S Injection method fixed at simultaneous injection Returned to normal condition P0110 Intake air temp. is fixed at 20°C (68°F) Returned to normal condition P0115 Engine coolant temp. is fixed at 80°(176°F) Returned to normal condition P0120 VTA is fixed at 0° The following condition must be repeated at least 2 times consecutively When closed throttle position switch is ON: 0.1 V x VTA x 0.95 V P0135 P0141 The heater circuit in witch an abnormality is detected is turned off Ignition switch OFF P0325 P0330 Max. timing retardation Ignition switch OFF P1300 Fuel cut IGF signal is detected for 6 consective ignitions P1605 Max. timing retardation Returned to normal condition 5. CHECK FOR INTERMITTENT PROBLEMS TOYOTA hand−held tester only: By putting the vehicle’s ECM in check mode, 1 trip detection logic is possible instead of 2 trip detection logic and sensitivity to detect open circuits is increased. This makes it easier to detect intermittent problems. (1) Clear the DTC (See step 2). (2) Set the check mode (See step 3). (3) Perform a simulation test (See page IN−18). (4) Check the connector and terminal (See page IN−28). (5) Handle the connector (See page IN−28). (6) Visual check and contact pressure (See page IN−28). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−8 DIAGNOSTICS − ENGINE 6. BASIC INSPECTION When the malfunction code is not confirmed in the DTC check, troubleshooting should be performed in the order for all possible circuits to be considered as the causes of the problems. In many cases, by carrying out the basic engine check shown in the following flow chart, the location causing the problem can be found quickly and efficiently. Therefore, use of this check is essential in engine troubleshooting. 1 Is battery positive voltage 11 V or more when engine is stopped? NO Charge or replace battery. NO Proceed to page ST−16, and continue to troubleshoot. NO Go to step 7. YES 2 Is engine cranked? YES 3 Does engine start? YES 4 Check air filter. PREPARATION: Remove air filter. CHECK: Visually check that the air cleaner element is not dirty or excessive oily. HINT: If necessary, clean the element with compressed air. First blow from inside thoroughly, then blow from outside of element. Inside Outside P04771 NG Repair or replace 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−9 DIAGNOSTICS − ENGINE OK 5 Check idle speed. PREPARATION: (a) Warm up engine to normal operating temperature. (b) Switch off all accessories. (c) Switch off air conditioning. (d) Shift transmission into ”N” position. (e) Connect the OBD II scan tool or TOYOTA hand−held tester to DLC3 on the vehicle. CHECK: Use CURRENT DATA to check the idle speed. OK: Idle speed: 650 ± 50 rpm NG Proceed to matrix chart of problem symptoms on page DI−19. OK 6 Check ignition timing. DLC1 PREPARATION: (a) Warm up engine to normal operating temperature. (b) Shift transmission into ”N” position. (c) Keep the engine speed at idle. (d) Using SST, connect terminals TE1 and E1 of DLC1. SST 09843−18020 (e) Connect a timing light probe to a high−tension cord. CHECK: Check ignition timing. OK: Ignition timing: 3° BTDC at idle SST E1 TE1 P09137 P23430 A00149 NG Proceed to page IG−1 and continue to troubleshoot. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−10 DIAGNOSTICS − ENGINE OK Proceed to matrix chart of problem symptoms on page DI−19. 7 Check fuel pressure. P09401 PREPARATION: (a) Be sure that enough fuel is in the tank. (b) Connect the TOYOTA hand−held tester to the DLC3. (c) Turn ignition switch ON and push TOYOTA hand−held tester main switch ON. (d) Use ACTIVE TEST mode to operate the fuel pump. (e) If you have no TOYOTA hand−held tester, connect the positive (+) and negative (−) leads from the battery to the fuel pump connector (See page SF−6). CHECK: Check for fuel pressure in the fuel return hose when it is pinched off. HINT: At this time, you will hear a fuel flowing noise. NG Proceed to page SF−6 and continue to troubleshoot. OK 8 Check for spark. P22893 PREPARATION: (a) Remove No.2 and No.3 cylinder head cover. (b) Disconnect high−tension cord from spark plug. (c) Remove spark plug. (d) Install the spark plug to the high−tension cord. (e) Ground the spark plug. (f) Disconnect injector connector. CHECK: Check if spark occurs while engine is being cranked. NOTICE: To prevent excess fuel being injected from the injectors during this test, don’t crank the engine for more than 5 − 10 seconds at a time. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−11 DIAGNOSTICS − NG ENGINE Proceed to page IG−1 and continue to troubleshoot. OK Proceed to matrix chart of problem symptoms on page DI−19. 7. ENGINE OPERATING CONDITION NOTICE: The values given below for ”Normal Condition” are representative values, so a vehicle may still be normal even if its value varies from those listed here. So do not decide whether a part is faulty or not solely according to the ”Normal Condition” here. (a) CARB mandated signals. TOYOTA hand−held tester display Measurement Item Normal Condition* FUEL SYS #1 Fuel System Bank 1 OPEN: Air−fuel ratio feedback stopped CLOSED: Air−fuel ratio feedback operating Idling after warming up: CLOSED CALC LOAD Calculator Load: Current intake air volume as a proportion of max. intake air volume Idling: 13.8 − 19.3% Racing without load (2,500 rpm): 17.6 − 25.2% Engine Coolant Temp. Sensor Value After warming up: 80 − 95°C (176 − 203°F) SHORT FT #1 Short−term Fuel Trim Bank 1 0 ± 20% LONG FT #1 Long−term Fuel Trim Bank 1 0 ± 20% ENGINE SPD Engine Speed Idling: 650 ± 50 rpm VEHICLE SPD Vehicle Speed Vehicle Stopped: 0 km/h (0 mph) IGN ADVANCE Ignition Advance: Ignition Timing of Cylinder No. 1 Idling: BTDC 0 − 11° Intake Air Temp. Sensor Value Equivalent to Ambient Temp. Air Flow Rate Through Mass Air Flow Meter Idling: 4.3 − 6.1 gm/sec. Racing without load (2,500 rpm): 21.2 − 30.4 gm/sec. Voltage Output of Throttle Position Sensor Calculated as a percentage: 0 V → 0%, 5 V → 100% Throttle Fully Closed: 7 − 11% Throttle Fully Open: 65 − 75% O2S B1, S1 Voltage Output of Oxygen Sensor Bank 1, Sensor 1 Idling: 0.1 − 0.9 V O2FT B1, S1 Oxygen Sensor Fuel Trim Bank 1, Sensor 1 (Same as SHORT FT #1) 0 ± 20% O2S B1, S2 Voltage Output of Oxygen Sensor Bank 1, Sensor 2 Driving (50 km/h, 31 mph): 0.1 − 0.9 V COOLANT TEMP. INTAKE AIR MAF THROTTLE POS ∗: If no conditions are specifically stated for ”ldling”, it means the shift lever is at N or P position, the A/C switch is OFF and all accessory switches are OFF. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−12 DIAGNOSTICS (b) − ENGINE TOYOTA Enhanced Signals. TOYOTA hand−held tester display Measurement Item Normal Condition* MISFIRE RPM Engine RPM for first misfire range Misfire 0: 0 rpm MISFIRE LOAD Engine load for first misfire range Misfire 0: 0 g/r Fuel injection time for cylinder No.1 Idling: 2.0 − 3.5 ms IAC STEP POS Intake Air Control Valve step position Opening position step motor type IAC valve Idling: 10 − 50 step STARTER SIG Starter Signal Cranking: ON CTP SW Closed Throttle Position Switch Signal Throttle Fully Closed: ON A/C SIG A/C Switch Signal A/C ON: ON PNP SW Park/Neutral Position Switch Signal P or N Position: ON Stop Light Switch Signal Stop light switch ON: ON FC IDL Fuel Cut Idle: Fuel cut when throttle valve fully closed, during deceleration Fuel cut operating: ON FC TAU Fuel Cut TAU: Fuel cut during very light load Fuel cut operating: ON CYL#1 − CYL#6 Ratio of revolution variation for each cylinder when variation is large INJECTOR STOP LIGHT SW IGNITION 0% Ignition rate for all cylinders every 1,000 revolutions 0 − 3,000 rpm EGR Gas Temp. Sensor Value EGR not operating: Temp. between intake air temp. and engine coolant temp. EGR System Operating Condition Idling: OFF Fuel Pressure Up VSV Signal High temp. restarting: ON FUEL PUMP Fuel Pump Signal Idling: ON TOTAL FT B1 Total Fuel Trim Bank 1: Average value for fuel trim system of bank 1 Idling: 0.8 − 1.2 V O2 LR B1, S1 Oxygen Sensor Lean Rich Bank 1, Sensor 1 Response time for oxygen sensor output to switch from lean to rich Idling after warmed up: 0 − 1,000 msec. O2 RL B1, S1 Oxygen Sensor Rich Lean Bank 1, Sensor 1 Response time for oxygen sensor output to switch from rich to lean Idling after warmed up: 0 − 1,000 msec. EGRT GAS EGR SYSTEM FUEL PRES UP VSV ∗: If no conditions are specifically stated for ”ldling”, it means the shift lever is at N or P position, the A/C switch is OFF and all accessory switches are OFF. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−13 DIAGNOSTICS − ENGINE DI5OV−03 DIAGNOSTIC TROUBLE CODE CHART HINT: Parameters listed in the chart may not be exactly the same as your reading due to the type of instrument or other factors. If a malfunction code is displayed during the DTC check in check mode, check the circuit for that code listed in the table below. For details of each code, turn to the page referred to under the ’’See page ’’ for the respecire ’’DTC No.’’ in the DTC chart. DTC No. (See Page) Detection Item Trouble Area MIL Memory P0100 (DI−20) Mass Air Flow Circuit Malfunction  Open or short in mass air flow meter circuit  Mass air flow meter  ECM  *1  P0101 (DI−25) Mass Air Flow Circuit Range/Performance Problem  Mass air flow meter  *1  P0110 (DI−26) Intake Air Temp. Circuit Malfunction  Open or short in intake air temp. sensor circuit  Intake air temp. sensor  ECM  *1  P0115 (DI−30) Engine Coolant Temp. Circuit Malfunction  Open or short in engine coolant temp. sensor circuit  Engine coolant temp. sensor  ECM  *1  P0116 (DI−34) Engine Coolant Temp. Circuit Range/Performance Problem  Engine coolant temp. sensor  Cooling system  *1  P0120 (DI−35) Throttle/Pedal Position Sensor/Switch ”A” Circuit Malfunction  Open or short in throttle position sensor circuit  Throttle position sensor  ECM  *1  P0121 (DI−39) Throttle/Pedal Position Sensor/Switch ”A” Circuit Range/Performance Problem  Throttle position sensor  *1  P0125 (DI−40) Insufficient Coolant Temp. for Closed Loop Fuel Control  Open or short in heated oxygen sensor circuit  Heated oxygen sensor  *1  P0130 (DI−43) Heated Oxygen Sensor Circuit Malfunction (Bank 1 Sensor 1)  Heated oxygen sensor  Fuel trim malfunction  *1  P0133 (DI−46) Heated Oxygen Sensor Circuit Slow Response (Bank 1 Sensor 1)  Heated oxygen sensor  *1  P0135 (DI−47) Heated Oxygen Sensor Heater Circuit Malfunction (Bank 1 Sensor 1)  Open or short in heater circuit of heated oxygen sensor  Heated oxygen sensor heater  ECM  *1  P0136 (DI−49) Heated Oxygen Sensor Circuit Malfunction (Bank 1 Sensor 2)  Heated oxygen sensor  *1  P0141 (DI−47) Heated Oxygen Sensor Heater Circuit Malfunction (Bank 1 Sensor 2)  Same as DTC No. P0135  *1  *1: MIL lights up 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−14 DIAGNOSTICS DTC No. (See Page) ENGINE MIL Memory System too Lean (Fuel Trim)  Air intake (hose loose)  Fuel line pressure, leak  Injector blockage  Heated oxygen sensor malfunction  Mass air flow meter  Engine coolant temp. sensor  *1  P0172 (DI−51) System too Rich (Fuel Trim)  Fuel line pressure  Injector leak, blockage  Heated oxygen sensor malfunction  Mass air flow meter  Engine coolant temp. sensor  *1  P0300 (DI−54) Random/Multiple Cylinder Misfire Detected P0301 P0302 P0303 P0304 P0305 P0306 (DI−54) Misfire Detected − Cylinder 1 − Cylinder 2 − Cylinder 3 − Cylinder 4 − Cylinder 5 − Cylinder 6  Ignition system  Injector  Fuel line pressure  EGR  Compression pressure  Valve clearance not to specification  Valve timing  Mass air flow meter  Engine coolant temp. sensor  *2  P0325 (DI−59) Knock Sensor 1 Circuit Malfunction  Open or short in knock sensor 1 circuit  Knock sensor 1 (looseness)  ECM  *1  P0330 (DI−59) Knock Sensor 2 Circuit Malfunction  Open or short in knock sensor 2 circuit  Knock sensor 2 (looseness)  ECM  *1  P0335 (DI−62) Crankshaft Position Sensor ”A” Circuit Malfunction  Open or short in crankshaft position sensor circuit for NE signal  Crankshaft position sensor for NE signal  Starter  ECM  *1  P0340 (DI−65) Camshaft Position Sensor Circuit Malfunction  Open or short in camshaft position sensor circuit  Camshaft position sensor  ECM  *1  P0385 (DI−67) Crankshaft Position Sensor ”B” Circuit Malfunction  Open or short in crankshaft position sensor circuit for NE2 signal  Crankshaft position sensor for NE2 signal  ECM  *1  Exhaust Gas Recirculation Flow Insufficient Detected  EGR valve stuck closed  Short in VSV circuit for EGR  Open in EGR gas temp. sensor circuit  EGR hose disconnected  ECM  *1  Exhaust Gas Recirculation Flow Excessive Detected  EGR valve stuck open  EGR VSV open malfunction  Open in VSV circuit for EGR  Short in EGR gas temp. sensor circuit  ECM  *1  P0171 (DI−51) P0401 (DI−69) P0402 (DI−80) Detection Item − Trouble Area *1: MIL lights up *2: MIL lights up or blinking 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−15 DIAGNOSTICS DTC No. (See Page) Detection Item − ENGINE Trouble Area *MIL Memory P0420 (DI−84) Catalyst System Efficiency Below Threshold  Three−way catalytic convertor  Open or short in heated oxygen sensor circuit  Heated oxygen sensor   P0500 (DI−87) Vehicle Speed Sensor Malfunction  Combination meter  Open or short in speed sensor circuit  ECM  Vehicle speed sensor   P0505 (DI−89) Idle Control System Malfunction  IAC valve is stuck or closed  Open or short in IAC valve circuit  Open or short A/C signal circuit  Air intake (hose loose)   P0510 (DI−93) Closed Throttle Position Switch Malfunction  Open in closed throttle position switch circuit  Closed throttle position switch  ECM   P1300 (DI−97) Igniter Circuit Malfunction  Open or short in IGF or IGT circuit from igniter to ECM  Igniter  ECM   P1335 (DI−102) Crankshaft Position Sensor Circuit Malfunction (during engine running)  Open or short in crankshaft position sensor circuit for NE signal  Crankshaft position sensor for NE signal  Starter  ECM −  P1500 (DI−103) Stater signal circuit Malfunction  Open or short in starter signal circuit  ECM −  P1600 (DI−105) ECM BATT Malfunction  Open in back up power source circuit  ECM   P1605 (DI−107) Knock Control CPU Malfunction  ECM   P1780 (DI−108) Park/Neutral Position Switch Malfunction  Short in park/neutral position switch circuit  Park/neutral position switch  ECM   *: − @@@ MIL does not light up,  @@@ MIL lights up 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−16 DIAGNOSTICS − ENGINE DI5OW−03 PARTS LOCATION A15824 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−17 DIAGNOSTICS − ENGINE DI5OX−03 TERMINALS OF ECM ECM Terminals E4 E5 E6 13 12 11 10 9 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1 6 5 4 3 2 1 26 25 24 23 22 21 20 19 18 17 16 15 14 16 15 14 13 12 11 10 9 12 11 10 9 8 7 E7 11 10 9 8 7 6 5 4 3 2 1 22 21 20 19 18 17 16 15 14 13 12 FI6526 Symbols (Terminals No.) Wiring Color BATT (E7 − 2) − E1 (E4 − 24) R − Y ↔ BR − B + B (E7 − 12) − E1 (E4 − 24) VCC (E5 − 1) − E2 (E5 − 9) IDL (E5 − 11) − E2 (E5 − 9) Condition STD Voltage (V) Always 9 − 14 Y ↔ BR − B IG switch ON 9 − 14 R − G ↔ BR − B IG switch ON 4.5 − 5.5 G − W ↔ BR − B VTA (E5 − 10) − E2 (E5 − 9) G − B ↔ BR − B IG switch ON and apply vacuum to the throttle opener Throttle valve fully closed 0−3 IG switch ON Throttle valve fully open 9 − 14 IG switch ON Throttle valve fully closed 0.3 − 0.8 IG switch ON Throttle valve fully open 3.2 − 4.9 VG (E5 − 2) − E21 (E5 − 16) G − BR Idling, N position, A/C switch OFF 1.1 − 1.5 THA (E5 − 3) − E2 (E5 − 9) L − Y ↔ BR − B Idling, Intake air temp. 20°C (68° F) 0.5 − 3.4 THW (E5 − 4) − E2 (E5 − 9) R − W ↔ BR − B Idling, Engine coolant temp. 80°C (176°F) 0.2 − 1.0 STA (E7 − 11) − E1 (E4 − 24) B − R ↔ BR − B Cranking IG switch ON #10 (E4 − 12) − E01 (E4 − 13) W − L ↔ BR #20 (E4 − 11) − E01 (E4 − 13) W − R ↔ BR #30 (E4 − 25) − E01 (E4 − 13) W − G ↔ BR Idling IG switch ON Idling IG switch ON Idling IG switch ON #40 (E4 − 2) − E01 (E4 − 13) Y ↔ BR Idling IG switch ON #50 (E4 − 1) − E01 (E4 − 13) Y − R ↔ BR Idling IG switch ON #60 (E4 − 15) − E01 (E4 − 13) Y − L ↔ BR Idling 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 6.0 or more 9 − 14 Pulse generation (See page DI−54) 9 − 14 Pulse generation (See page DI−54) 9 − 14 Pulse generation (See page DI−54) 9 − 14 Pulse generation (See page DI−54) 9 − 14 Pulse generation (See page DI−54) 9 − 14 Pulse generation (See page DI−54) Brought to you by BirfMark DI−18 DIAGNOSTICS IGT (E4 − 23) − E1 (E4 − 24) B − G ↔ BR − B IGF (E4 − 17) − E1 (E4 − 24) B − Y ↔ BR − B − ENGINE Idling IG switch ON Disconnect igniter connector Pulse generation (See page DI−97) 4.5 − 5.5 Idling Pulse generation (See page DI−97) G1 (E6 − 11) − G − (E6 − 6) R↔L Idling Pulse generation (See page DI−62) G2 (E6 − 10) − G − (E6 − 6) G↔L Idling Pulse generation (See page DI−62) NE (E6 − 12) − G − (E6 − 6) W↔L Idling Pulse generation (See page DI−62) NE2 (E6 − 5) − G − (E6 − 6) BR ↔ L Idling Pulse generation (See page DI−62) Idling 9 − 14 IG switch ON 0−3 W (E7 − 4) − E1 (E4 − 24) Y − R ↔ BR − B EGR (E4 − 22) − E1 (E4 − 24) L − W ↔ BR − B IG switch ON 9 − 14 ISC1 (E4 − 7) − E01 (E4 − 13) R − G ↔ BR IG switch ON 9 − 14 ISC2 (E4 − 6) − E01 (E4 − 13) R − B ↔ BR IG switch ON 9 − 14 ISC3 (E4 − 5) − E01 (E4 − 13) G − Y ↔ BR IG switch ON 9 − 14 ISC4 (E4 − 4) − E01 (E4 − 13) L − Y ↔ BR IG switch ON 9 − 14 OX1 (E5 − 5) − E1 (E4 − 24) L ↔ BR − B Maintain engine speed at 2,500 rpm for 2 mins. after warming up Pulse generation OX2 (E5 − 13) − E1 (E4 − 24) W ↔ BR − B Maintain engine speed at 2,500 rpm for 2 mins. after warming up Pulse generation HT1 (E6 − 1) − E03 (E6 − 16) GR ↔ BR HT2 (E6 − 7) − E03 (E6 − 16) O ↔ BR KNK1 (E5 − 6) − E1 (E4 − 24) W ↔ BR − B Idling KNK2 (E5 − 14) − E1 (E4 − 24) L − W ↔ BR − B Idling Pulse generation (See page DI−62) SPD (E7 − 8) − E1 (E4 − 24) L − W ↔ BR − B IG switch ON Rotate driving wheel slowly. Pulse generation TE1 (E5 − 7) − E1 (E4 − 24) L ↔ BR − B A/C (E7 − 7) − E1 (E4 − 24) B − W ↔ BR − B THG (E4 − 19) − E2 (E5 − 9) G − Y ↔ BR − B FC (E4 − 14) − E1 (E4 − 24) R − W ↔ BR − B FPU (E4 − 21) − E1 (E4 − 24) L − R ↔ BR − B SDL (E7 − 6) − E1 (E4 − 24) W ↔ BR − B Idling IG switch ON Idling IG switch ON Below 3.0 9 − 14 Below 3.0 9 − 14 Pulse generation (See page DI−62) IG switch ON 9 − 14 Idling, A/C switch ON 9 − 14 Idling, A/C switch OFF Below 2.0 IG switch ON 4.5 − 5.5 IG switch ON 9 − 14 Idling 0−3 IG switch ON 9 − 14 Restarting at high engine coolant temp. 0−3 During transmission 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Pulse generation Brought to you by BirfMark DI−19 DIAGNOSTICS − ENGINE DI5OY−03 PROBLEM SYMPTOMS TABLE When the malfunction code is not confirmed in the DTC check and the problem still can not be confirmed in the basic inspection, then proceed to this step and perform troubleshooting according to the numbered order given in the table below. Symptom Suspect Area See page Engine does not crank (Does not start) 1. Starting system ST−16 No initial combustion (Does not start) 1. ECM power source circuit 2. Fuel pump control circuit DI−110 DI−115 No complete combustion (Does not start) 1. Fuel pump control circuit DI−115 Engine cranks normally (Difficult to start) 1. Starter signal circuit 2. Fuel pump control circuit 3. Compression DI−103 DI−115 EM−3 Cold engine (Difficult to start) 1. Starter signal circuit 2. Fuel pump control circuit DI−103 DI−115 Hot engine (Difficult to start) 1. Starter signal circuit 2. Fuel pressure control circuit 3. Fuel pump control circuit DI−103 DI−125 DI−115 High engine idle speed (Poor idling) 1. A/C signal circuit 2. ECM power source circuit AC−5 DI−110 Low engine idle speed (Poor idling) 1. A/C signal circuit 2. Fuel pump control circuit AC−5 DI−115 Rough idling (Poor idling) 1. Compression 2. Fuel pump control circuit EM−3 DI−115 Hunting (Poor idling) 1. ECM power source circuit 2. Fuel pump control circuit DI−110 DI−115 Hesitation/Poor acceleration (Poor driveability) 1. Fuel pump control circuit 2. A/T faulty DI−115 DI−147 Surging (Poor driveability) 1. Fuel pump control circuit DI−115 Soon after starting (Engine stall) 1. Fuel pump control circuit DI−115 During A/C operation (Engine stall) 1. A/C signal circuit 2. Engine control module (ECM) IN−18 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 AC−5 Brought to you by BirfMark DI−20 DIAGNOSTICS − ENGINE DI5OZ−02 CIRCUIT INSPECTION DTC P0100 Mass Air Flow Circuit Malfunction CIRCUIT DESCRIPTION The mass air flow meter uses a platinum hot wire. The hot wire air flow meter consists of a platinum hot wire, thermistor and a control circuit installed in a plastic housing. The hot wire air flow meter works on the principle that the hot wire and thermistor located in the intake air bypass of the housing detect any changes in the intake air temperature. The hot wire is maintained at the set temperature by controlling the current flow through the hot wire. This current flow is then measured as the output voltage of the air flow meter. The circuit is constructed so that the platinum hot wire and thermistor provide a bridge circuit, with the power transistor controlled so that the potential of ”A” and ”B” remains equal to maintain the set temperature. B+ Thermistor Power Transistor Platinum Hot Wire B A Output Voltage Platinum Hot Wire Thermistor FI6929 P22263 A00152 DTC No. P0100 DTC Detecting Condition Trouble Area Open or short in mass air flow meter circuit with engine speed 4,000 rpm or less. S Open or short in mass air flow meter circuit S Mass air flow meter S ECM If the ECM detects DTC” P0100” it operates the fail safe function, keeping the ignition timing and injection volume constant and marking it possible to drive the vehicle. HINT: After confirming DTC P0100 use the OBD II scan tool or TOYOTA hand−held tester to confirm the mass air flow ratio from ”CURRENT DATA”. Mass Air Flow Value (gm/sec.) Approx. 0 439.0 or more Malfunction S Mass air flow meter power source open S VG circuit open or short S E21 circuit open 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−21 DIAGNOSTICS − ENGINE WIRING DIAGRAM R−Y W 2 2 4 1 3 2 2 EFI Main 2 Relay R/B No.2 Y−R 7 R EA2 Fusible Link R 3 MRLY E7 G 2 VG E5 1 EB1 1 2 BR FL MAIN 1 F8 EFI 2 Y−R 2 ECM B+ 5 BR Battery 16 E21 E5 E1 EB Mass Air Flow Meter P22419 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−22 DIAGNOSTICS − ENGINE INSPECTION PROCEDURE 1 Connect the OBD II scan tool or TOYOTA hand−held tester, and read value of mass air flow rate. PREPARATION: (a) Remove the fuse cover on the instrument panel. (b) Connect the OBD II scan tool or TOYOTA hand−held tester to the DLC3. (c) Turn ignition switch ON and OBD II scan tool or TOYOTA hand−held tester main switch ON. (d) Start the engine. CHECK: Read mass air flow rate on the OBD II scan tool or TOYOTA hand−held tester. RESULT: Mass air flow rate (gm/sec.) 2 Type I Type II Approx. 0 gm/sec. 439.0 gm/sec. or more Type I Go to step 2. Type II Go to step 5. Check voltage of mass air flow meter power source. PREPARATION: (a) Disconnect the mass air flow meter connector. (b) Turn ignition switch ON. CHECK: Measure voltage between terminal 1 of mass air flow meter connector and body ground. OK: Voltage: 9 − 14 V ON BE6653 P24652 A00201 NG Check for open in harness and connector between EFI main relay (Marking: EFI) and mass air flow meter (See page IN−28). OK 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−23 DIAGNOSTICS 3 − ENGINE Check voltage between terminal VG of ECM and body ground. (+) (−) VG P24653 PREPARATION: (a) Remove instrument panel speaker No.1 panel (See pageSF−65). (b) Start the engine. CHECK: Measure voltage between terminal VG of ECM and body ground while engine is idling. OK: Voltage: 1.1 − 1.5 V (P or N position and A/C switch OFF) OK Check and replace ECM (See page IN−28). NG 4 Check for open and short in harness and connector between mass air flow meter and ECM (See page IN−28). NG Repair or replace harness or connector. OK Replace mass air flow meter. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−24 DIAGNOSTICS 5 − ENGINE Check continuity between terminal E21 of ECM and body ground. PREPARATION: Remove instrument panel speaker No.1 panel (See pageSF−65). CHECK: Check continuity between terminal E21 of ECM and body ground. OK: Continuity (1 Ω or less) (+) (−) E21 P24654 NG Check and replace ECM (See page IN−28). OK 6 Check for open in harness and connector between mass air flow meter and ECM (See page IN−28). NG Repair or replace harness or connector. OK Replace mass air flow meter. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−25 DIAGNOSTICS − ENGINE DI5P0−02 DTC P0101 Mass Air Flow Circuit Range/Performance Problem CIRCUIT DESCRIPTION Refer to DTC P0100 (Mass Air Flow Circuit Malfunction) on page DI−20. DTC No. P0101 DTC Detecting Condition Trouble Area Conditions (a) and (b) continue with engine speed 900 rpm or less (2 trip detection logic): (a) Closed throttle position switch: ON (b) Mass air flow meter output > 2.2 V Conditions (a) and (b) continue with engine speed 1500 rpm (2 trip detection logic): (a) Mass air flow meter output < 1 V (b) VTA y 0.72 V S Mass air flow meter WIRING DIAGRAM Refer to DTC P0100 (Mass Air Flow Circuit Malfunction) on page DI−20 for the WIRING DIAGRAM. INSPECTION PROCEDURE 1 Are there any other codes (besides DTC P0101) being output? YES Go to relevant DTC chart. NO Replace mass air flow meter. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−26 DIAGNOSTICS − ENGINE DI5P1−02 DTC P0110 Intake Air Temp. Circuit Malfunction CIRCUIT DESCRIPTION (fig.1) 30 20 10 Acceptable Resistance kΩ 5 3 2 1 0.5 0.3 0.2 0.1 − 20 (− 4) 0 32 20 68 40 104 60 140 80 176 100 212 Temp.°C (F°) FI4741 DTC No. P0110 The intake air temperature sensor is built into the air flow meter and senses the intake air temperature. A thermistor built in the sensor changes the resistance value according to the intake air temperature. The lower the intake air temperature, the greater the thermistor resistance value, and the higher the intake air temperature, the lower the thermistor resistance value (See fig.1). The intake air temperature sensor is connected to the ECM (See next page). The 5 V power source voltage in the ECM is applied to the intake air temperature sensor from the terminal THA via a resistor R. That is, the resistor R and the intake air temperature sensor are connected in series. When the resistance value of the intake air temperature sensor changes in accordance with changes in the intake air temperature, the potential at terminal THA also changes. Based on this signal, the ECM increases the fuel injection volume to improve driveability during cold engine operation. If the ECM detects the DTC ”P0110”, it operates the fail safe function in which the intake air temperature is assumed to be 20°C (68°F). Intake Air Temp. °C (°F) Resistance (kΩ) Voltage (V) −20 (−4) 16.2 4.3 0 (32) 5.9 3.4 20 (68) 2.5 2.4 40 (104) 1.1 1.4 60 (140) 0.6 0.9 80 (176) 0.3 0.5 100 (212) 0.1 0.2 DTC Detecting Condition Open or short in intake air temp. sensor circuit Trouble Area S Open or short in intake air temp. sensor circuit S Intake air temp. sensor S ECM HINT: After confirming DTC P110 use the OBD II scan tool or TOYOTA hand−held tester to confirm the intake air temp. from ”CURRENT DATA”. Temp. Displayed Malfunction − 40°C (− 40°F) Open circuit 140°C (284°F) or more Short circuit 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−27 DIAGNOSTICS − ENGINE WIRING DIAGRAM ECM Intake Air Temp. Sensor (Inside the mass air flow meter) 5V 3 L−Y 3 THA E5 4 BR−B 9 E2 E5 R E1 P22420 A00484 INSPECTION PROCEDURE HINT: If DTCs P0110 (Intake Air Temp. Circuit Malfunction), P0115 (Engine Coolant Temp. Circuit Malfunction), P0120 (Throttle/Pedal Position Sensor/Switch ”A” Circuit Malfunction) are output simultaneously, E2 (Sensor Ground) may be open. 1 Connect the OBD II scan tool or TOYOTA hand−held tester, and read value of intake air temperature. PREPARATION: (a) Remove the fuse cover on the instrument panel. (b) Connect the OBD II scan tool or TOYOTA hand−held tester to DLC3. (c) Turn ignition switch ON and OBD II scan tool or TOYOTA hand−held tester main switch ON. CHECK: Read temp. value on the OBD II scan tool or TOYOTA hand−held tester. OK: Same as actual intake air temp. HINT: S If there is open circuit, push OBD II scan tool or TOYOTA hand−held tester indicates − 40°C (− 40°F). S If there is short circuit, OBD II scan tool or TOYOTA hand−held tester indicates 140°C (284°F) or more. NG − 40°C (− 40°F) ....Go to step 2. 140°C (284°F) or more ....Go to step 4. OK Check for intermittent problems (See page DI−3). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−28 DIAGNOSTICS 2 − ENGINE Check for open in harness or ECM. PREPARATION: (a) Disconnect the mass air flow meter connector. (b) Connect sensor wire harness terminals together. (c) Turn ignition switch ON. CHECK: Read temp. value on the OBD II scan tool or TOYOTA hand− held tester. OK: Temp. value: 140°C (284°F) or more ON Intake Air Temp. Sensor 3 3 E5 ECM 5V THA 9 E2 E5 E1 4 BE6653 FI7055 A00154 A00154 OK Confirm good connection at sensor. If OK, replace mass air flow meter. NG 3 Check for open in harness or ECM. PREPARATION: (a) Remove instrument panel speaker No.1 panel (See page SF−65). (b) Connect between terminals THA and E2 of ECM connector. HINT: Mass air flow meter connector is disconnected. Before checking, do a visual and contact pressure check for the ECM connector (See page IN−28). (c) Turn ignition switch ON. CHECK: Read temp. value on the OBD II scan tool or TOYOTA hand−held tester. OK: Temp. value: 140°C (284°F) or more ON Intake Air Temp. Sensor 3 E5 ECM 5V THA 9 E2 E5 THA E1 E2 BE6653 FI7057 P24655 A00150 OK Open in harness between terminals E2 or THA, repair or replace harness. NG Confirm good connection at ECM. If OK, replace ECM (See page IN−28). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−29 DIAGNOSTICS 4 − ENGINE Check for short in harness and ECM. ON Intake Air Temp. Sensor 3 3 E5 ECM 5V THA 9 E2 E5 4 BE6653 FI7054 E1 PREPARATION: (a) Disconnect the mass air flow meter connector. (b) Turn ignition switch ON. CHECK: Read temp. value on the OBD II scan tool or TOYOTA hand− held tester. OK: Temp. value: − 40°C (− 40°F) A00151 OK Replace mass air flow meter. NG 5 Check for short in harness or ECM. ON ECM 5V Intake Air Temp. Sensor THA E2 E1 BE6653 FI7056 P19798 PREPARATION: (a) Remove instrument panel speaker No.1 panel (See page SF−65). (b) Disconnect the E5 connector of ECM. HINT: Mass air flow meter connector is disconnected. (c) Turn ignition switch ON. CHECK: Read temp. value on the OBD II scan tool or TOYOTA hand− held tester. OK: Temp. value: − 40°C (− 40°F) E5 connector A00155 OK Repair or replace harness or connector (See page IN−28). NG Check and replace ECM (See page IN−28). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−30 DIAGNOSTICS − ENGINE DI5P5−02 DTC P0115 Engine Coolant Temp. Circuit Malfunction CIRCUIT DESCRIPTION A thermistor built into the engine coolant temperature sensor changes the resistance value according to the engine coolant temperature. The structure of the sensor and connection to the ECM is the same as in the intake air temp. circuit malfunction shown on page DI−26. If the ECM detects the DTC P0115, it operates the fail safe function in which the engine coolant temp. is assumed to be 80°C (176 °F). DTC No. P0115 Detection Item Trouble Area S Open or short in engine coolant temp. sensor circuit S Engine coolant temp. sensor S ECM Open or short in engine coolant temp. sensor circuit HINT: After confirming DTC P0115 use the OBD II scan tool or TOYOTA hand−held tester to confirm the engine coolant temp. from CURRENT DATA. Temp. Displayed Malfunction − 40°C (− 40°F) Open circuit 140°C (284°F) or more Short circuit WIRING DIAGRAM ECM 5V Engine Coolant Temp. Sensor 2 R−W 4 THW E5 1 BR−B 9 E2 E5 P22421 E1 A00485 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−31 DIAGNOSTICS − ENGINE INSPECTION PROCEDURE HINT: If DTC is P0110 (Intake Air Temp. Circuit Malfunction), P0115 (Engine Coolant Temp. Circuit Malfunction), P0120 (Throttle/Pedal Position Sensor/Switch ”A” Circuit Malfunction) are output simultaneously, E2 (Sensor Ground) may be open. 1 Connect the OBD II scan tool or TOYOTA hand−held tester, and read value of engine coolant temperature. PREPARATION: (a) Remove the fuse cover on the instrument panel. (b) Connect the OBD II scan tool or TOYOTA hand−held tester to the DLC3. (c) Turn ignition switch ON and push the OBD II scan tool or TOYOTA hand−held tester main switch ON. CHECK: Read temperature value on the OBD II scan tool or TOYOTA hand−held tester. OK: Same as actual engine coolant temperature. HINT: S If there is open circuit, OBD II scan tool or TOYOTA hand−held tester indicates − 40°C (− 40°F). S If there is short circuit, OBD II scan tool or TOYOTA hand−held tester indicates 140°C (284°F) or more. NG −40°C (−40°F) ... Go to step 2. 140°C (284°F) or more ... Go to step 4. OK Check for intermittent problems (See page DI−3). 2 Check for open in harness or ECM. ON Engine Coolant Temp. Sensor 2 1 BE6653 FI7055 ECM 4 E5 THW 5V 9 E2 E5 E1 A00156 PREPARATION: (a) Disconnect the engine coolant temp. sensor connector. (b) Connect sensor wire harness terminals together. (c) Turn ignition switch ON. CHECK: Read temp. value on the OBD II scan tool or TOYOTA hand− held tester. OK: Temp. value: 140°C (284°F) or more OK Confirm good connection at sensor. If OK, replace engine coolant temp. sensor. NG 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−32 DIAGNOSTICS 3 − ENGINE Check for open in harness or ECM. PREPARATION: (a) Remove instrument panel speaker No.1 panel (See page SF−65). (b) Connect between terminals THW and E2 of ECM connector. HINT: Engine coolant temp. sensor connector is disconnected. Before checking, do a visual and contact pressure check for the ECM connector (See page IN−28). (c) Turn ignition switch ON. CHECK: Read temperature value on the OBD II scan tool or TOYOTA hand−held tester. OK: Temperature value: 140°C (284°F) or more ON Engine Coolant Temp. Sensor 2 ECM 5V 4 THW E5 1 THW BE6653 FI7057 P24656 9 E2 E5 E1 E2 A00157 OK Open in harness between terminals E2 or THW, repair or replace harness. NG Confirm good connection at ECM. If OK, replace ECM (See page IN−28). 4 Check for short in harness or ECM. ON Engine Coolant Temp. Sensor 4 ECM 5V E5 THW 9 E2 E5 BE6653 FI7054 E1 PREPARATION: (a) Disconnect the engine coolant temp. sensor connector. (b) Turn ignition switch ON. CHECK: Read temperature value on the OBD II scan tool or TOYOTA hand−held tester. OK: Temperature value: − 40°C (− 40°F) A00158 OK Replace engine coolant temp. sensor. NG 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−33 DIAGNOSTICS 5 ENGINE Check for short in harness or ECM. ON Engine Coolant Temp. Sensor ECM 5V THW E2 E1 BE6653 FI7056 P19798 − PREPARATION: (a) Remove instrument panel speaker No.1 panel (See page SF−65). (b) Disconnect the E5 connector of ECM. HINT: Engine coolant temp. sensor connector is disconnected. (c) Turn ignition switch ON. CHECK: Read temperature value on the OBD II scan tool or TOYOTA hand−held tester. OK: Temperature value: − 40°C (− 40°F) E5 connector A00159 OK Repair or replace harness or connector. NG Check and replace ECM (See page IN−28). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−34 DIAGNOSTICS − ENGINE DI5P6−02 DTC P0116 Engine Coolant Temp. Circuit Range/ Performance Problem CIRCUIT DESCRIPTION Refer to DTC P0115 (Engine Coolant Temp. Circuit Malfunction) on page DI−30. DTC No.. DTC Detecting Condition Trouble Area If THW y 10°C (50°F), 2 min. or more after starting engine, engine coolant temp. sensor value is 35°C (95°F) or less (2 trip detection logic) P0116 If −7°C (19.4°F) x THW < 10°C (50°F), 5 min. or more after starting engine, engine coolant temp. sensor value 35°C (95°F) or less (2 trip detection logic) S Engine coolant temp. sensor S Cooling system If THW < −7°C (19.4°F), 20 min. or more after starting engine, engine coolant temp. sensor value is 35°C (95°F) or less (2 trip detection logic) INSPECTION PROCEDURE HINT: If DTC P0115 (Engine Coolant Temp. Circuit Malfunction) and P0116 (Engine Coolant Temp. Circuit Range/ Performance) are output simultaneously, engine coolant temp. sensor circuit may be open. Perform troubleshooting of DTC P0115 first. 1 Are there any other codes (besides DTC P0116) being output? YES Go to relevant DTC chart. NO 2 Check thermostat (See page CO−9). NG Replace the thermostat. OK Replace engine coolant temp. sensor. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−35 DIAGNOSTICS − ENGINE DI5P7−02 DTC P0120 Throttle/Pedal Position Sensor/Switch ”A” Circuit Malfunction CIRCUIT DESCRIPTION Throttle Position Sensor ECM 5V VCC B+ VTA IDL E2 FI6571 DTC No. P0120 The throttle position sensor is mounted in the throttle body and detects the throttle valve opening angle. When the throttle valve is fully closed, the IDL contacts in the throttle position sensor are on, so the voltage at the terminal IDL of the ECM becomes 0 V. At this time, a voltage of approximately 0.3 − 0.8 V is applied to terminal VTA of the ECM. When the throttle valve is opened, the IDL contacts go off and thus the power source voltage of approximately 12 V in the ECM is applied to the terminal IDL of the ECM. The voltage applied to the terminal VTA of the ECM increases in proportion to the opening angle of the throttle valve and becomes approximately 3.2 − 4.9 V when the throttle valve is fully opened. The ECM judges the vehicle driving conditions from these signals input from terminals VTA and IDL, and uses them as one of the conditions for deciding the air−fuel ratio correction, power increase correction and fuel−cut control etc. DTC Detecting Condition Trouble Area Condition (a) or (b) continues (a) VTA < 0.1 V, and closed throttle position switch is OFF (b) VTA > 4.9 V S Open or short in throttle position sensor circuit S Throttle position sensor S ECM HINT: S S If there is open circuit in IDL line, DTC P0120 does not indicate. After confirming DTC P0120 use the OBD II scan tool or TOYOTA hand−held tester to confirm the throttle valve opening percentage and closed throttle position switch condition. Throttle valve opening position expressed as percentage Trouble Area Throttle valve fully closed Throttle valve fully open 0% 0% VCC line open VTA line open or short Approx. 99 % Approx. 100 % E2 line open 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−36 DIAGNOSTICS − ENGINE WIRING DIAGRAM Throttle Position Sensor ECM R−G 1 VCC E5 3 G−B 10 VTA E5 2 G−W 11 IDL E5 1 BR−B 4 * 9 E5 5V B+ E2 E1 * Closed Throttle Position Switch A00483 P22422 INSPECTION PROCEDURE HINT: If DTCs P0110 (Intake Air Temp. Circuit Malfunction), P0115 (Engine Coolant Temp. Circuit Malfunction), P0120 (Throttle/Pedal Position Sensor/Switch ”A” Circuit Malfunction) are output simultaneously, E2 (Sensor Ground) may be open. 1 Connect the OBD II scan tool or TOYOTA hand−held tester and read the throttle valve opening percentage. PREPARATION: (a) Remove the fuse cover on the instrument panel. (b) Connect the OBD II scan tool or TOYOTA hand−held tester to DLC3. (c) Turn ignition switch ON and push the OBD II scan tool or TOYOTA hand−held tester main switch ON. CHECK: Read the throttle valve opening percentage. OK: OK FI7052 Throttle valve Throttle valve opening position expressed as percentage Fully open Approx. 75 % Fully closed Approx. 10 % Check for intermittent problems (See page DI−3). NG 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−37 DIAGNOSTICS 2 − ENGINE Check voltage between terminal 1 of wire harness side connector and body ground. PREPARATION: (a) Disconnect the throttle position sensor connector. (b) Turn ignition switch ON. CHECK: Measure voltage between terminal 1 of wire harness side connector and body ground. OK: Voltage: 4.5 − 5.5 V ON 1 BE6653 P24657 A00160 NG Go to step 5. OK 3 Check throttle position sensor (See page SF−42). NG Replace throttle position sensor. OK 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−38 DIAGNOSTICS 4 − ENGINE Check voltage between terminals VTA and E2 of ECM. PREPARATION: (a) Remove instrument panel speaker No.1 panel (See page SF−65). (b) Turn ignition switch ON. CHECK: Measure voltage between terminals VTA and E2 of ECM. OK: ON VTA (+) E2 (−) BE6653 P24658 A00161 NG Throttle valve Voltage Fully closed 0.3 − 0.8 V Fully open 3.2 − 4.9 V Check for open and short in harness and connector between ECM and throttle position sensor (VTA line) (See page IN−28). OK Check and replace ECM (See page IN−28). 5 Check voltage between terminals VCC and E2 of ECM. ON VCC (+) (−) BE6653 P24659 E2 A00162 PREPARATION: (a) Remove instrument panel speaker No.1 panel (See page SF−65). (b) Turn ignition switch ON. CHECK: Measure voltage between terminals VCC and E2 of ECM connector. OK: Voltage: 4.5 − 5.5 V NG Check and replace ECM (See page IN−28). OK Check for open in harness and connector between ECM and sensor (VCC line) (See page IN−28). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−39 DIAGNOSTICS − ENGINE DI5P8−02 DTC P0121 Throttle/Pedal Position Sensor/Switch ”A” Circuit Range/Performance Problem CIRCUIT DESCRIPTION Refer to DTC P0120 (Throttle/Pedal Position Sensor/Switch "A" Circuit Malfunction) on page DI−35. DTC No. DTC Detection Condition Trouble Area P0121 After the vehicle speed has been exceeded 30 km/h (19 mph) even once, the output value of the throttle position sensor is out of the applicable range while the vehicle speed between 30 km/h (19 mph) and 0 km/h (0 mph). S Throttle position sensor INSPECTION PROCEDURE 1 Are there any other codes (besides DTC P0121) being output? YES Go to relevant DTC chart. NO Replace throttle position sensor. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−40 DIAGNOSTICS − ENGINE DI5P9−02 DTC P0125 Insufficient Coolant Temp. for Closed Loop Fuel Control CIRCUIT DESCRIPTION To obtain a high purification rate for the CO, HC and NOx components of the exhaust gas, a three−way catalytic converter is used, but for the most efficient use of the three−way catalytic converter, the air−fuel ratio must be precisely controlled so that it is always close to the stoichiometric air−fuel ratio. The oxygen sensor has the characteristic where by its output voltage changes suddenly in the vicinity of the stoichiometric air−fuel ratio. This characteristic is used to detect the oxygen concentration in the exhaust gas and provide feedback to the computer for control of the air−fuel ratio. When the air−fuel ratio becomes LEAN, the oxygen concentration in the exhaust increases and the oxygen sensor informs the ECM of the LEAN condition (small electromotive force: 0 V). When the air−fuel ratio is RICHER than the stoichiometric air−fuel ratio the oxygen concentration in the exhaust gas in reduced and the oxygen sensor informs the ECM of the RICH condition (large electromotive force: 1 V). The ECM judges by the electromotive force from the oxygen sensor whether the air−fuel ratio is RICH or LEAN and controls the injection time accordingly. However, if malfunction of the oxygen sensor causes output of abnormal electromotive force, the ECM is unable to perform accurate air−fuel ratio control. The heated oxygen sensors include a heater which heats the zirconia element. The heater is controlled by the ECM. When the intake air volume is low (the temp. of the exhaust gas is low) current flows to the heater to heat the sensor for accurate oxygen concentration detection. Ideal Air−Fuel Mixture Flange Platinum Electrode Solid Electrolyte (Zirconia Element) Platinum Electrode Heater Coating (Ceramic) Cover Output Voltage Atmosphere Richer − Air Fuel Ratio − Leaner Exhaust Gas P21242 FI7210 A00027 DTC No. P0125 DTC Detecting Condition After the engine is warmed up, heated oxygen sensor (bank 1 sensor 2) output does not indicate RICH even once when conditions (a), (b) and (c) continue for at least 1.5 min. (a) Engine speed: 1,500 rpm or more (b) Vehicle speed: 40 − 100 km/h (25 − 62 mph) (c) Closed throttle position switch: OFF Trouble Area S Open or short in heated oxygen sensor (bank 1 sensor 1) circuit S Heated oxygen sensor (bank1 sensor 1) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−41 DIAGNOSTICS − ENGINE HINT: After confirming DTC P0125 use the OBD II scan tool or TOYOTA hand−held tester to confirm voltage output of heated oxygen sensor (bank 1 sensor 1) from CURRENT DATA. If voltage output of heated oxygen sensor (bank 1 sensor 1) is 0 V, heated oxygen sensor (bank 1 sensor 1) circuit may be open or short. WIRING DIAGRAM ECM B+ 7 R EA2 EFI 2 2 BR 2 EB From Battery 2 1 3 MRLY 5 OX1 E5 Heated Oxygen Sensor E1 (bank 1 sensor 1) 1 4 HT1 GR E6 1 W 3 BR−B 2 L Y−R 2 4 BR−B 2 1 Y−R Heated Oxygen Sensor (bank 1 sensor 2) Y−R 4 3 R/B No.2 EFI Main Relay 2 2 1 EB1 R−Y Y−R 3 E7 R E03 13 OX2 E5 E1 BR−B O 24 E1 E4 7 HT2 E6 E03 EC P22423 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−42 DIAGNOSTICS − ENGINE INSPECTION PROCEDURE 1 Connect the OBD II scan tool or TOYOTA hand−held tester and read value for voltage output of heated oxygen sensor). PREPARATION: (a) Remove the fuse cover on the instrument panel. (b) Connect the OBD II scan tool or TOYOTA hand−held tester to the DLC3. (c) Warm up engine to normal operating temp. CHECK: Read voltage output of heated oxygen sensor (bank 1 sensor 1) when engine is suddenly raced. HINT: Perform quick racing to 4,000 rpm 3 times using accelerator pedal. OK: Heated oxygen sensor (bank 1 sensor 1) output a RICH signal (0.45 V or more) at least once. OK Check and replace ECM (See page IN−28). NG 2 Check for open and short in harness and connector between ECM and heated oxygen sensor (bank1 sensor 1) (See page IN−28). NG Repair or replace harness or connector. OK Replace heated oxygen sensor (bank 1 sensor 1). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−43 DIAGNOSTICS − ENGINE DI5PA−02 DTC P0130 Heated Oxygen Sensor Circuit Malfunction (Bank 1 Sensor 1) CIRCUIT DESCRIPTION Refer to DTC P0125 (Insufficient Coolant Temp. for Closed Loop Fuel Control) on page DI−40. DTC No. P0130 DTC Detecting Condition Trouble Area Voltage output of heated oxygen sensor (bank 1 sensor 1) remains at 0.4 V or more, or 0.55 V or less, during idling after the engine is warmed up (2 trip detection logic) S Heated oxygen sensor (bank 1 sensor 1) S Fuel trim malfunction HINT: Sensor 1 refers to the sensor closer to the engine body. The heated oxygen sensor’s output voltage and the short−term fuel trim value can be read using the OBD II scan tool or TOYOTA hand−held tester. WIRING DIAGRAM Refer to DTC P0125 (Insufficient Coolant Temp. for Closed Loop Fuel Control) on page DI−35 for WIRING DIAGRAM. CONFIRMATION DRIVING PATTERN Vehicle Speed 50 − 65 km/h (31 − 40 mph) Idling IG SW OFF (4) (3) (5) (1)(2) 1 − 3 min. 1 min. Time FI7130 (1) Connect the TOYOTA hand−held tester to the DLC3. (2) Switch the TOYOTA hand−held tester from normal mode to check mode (See page DI−3). (3) Start the engine and warm it up withe all accessory switches OFF. (4) Drive the vehicle at 50 − 65 km/h (31 − 40 mph) for 1 − 3 min. to warm up the heated oxygen sensor. (5) Let the engine idle for 1 min. HINT: If a malfunction exists, the MIL will light up during step (5). NOTICE: If the conditions in this test are not strictly followed, detection of the malfunction will not be possible. If you do not have a TOYOTA hand−held tester, turn the ignition switch OFF after performing steps (3) to (5), then perform steps (3) to (5) again. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−44 DIAGNOSTICS − ENGINE INSPECTION PROCEDURE 1 Check for open and short in harness and connector between ECM and heated oxygen sensor (bank 1 sensor 1) (See page IN−28). NG Repair or replace harness or connector (See page IN−28). OK 2 Check for heated oxygen sensor (bank 1 sensor 1) data. PREPARATION: (a) Remove the fuse cover on the instrument panel. (b) Connect the OBD II scan tool or TOYOTA hand−held tester to the DLC3. (c) Warm up engine to normal operating temp. CHECK: Read the heated oxygen sensor (bank 1 sensor 1) output voltage and short−term fuel trim. RESULT: Pattern Heated oxygen sensor (bank 1 sensor 1) output voltage Short−term fuel trim 1 Lean condition (Changes at 0.55 V or less) Changes at about +20 % 2 Rich condition (Changes at 0.4 V or more) 3 Changes at about −20 % Except 1 and 2 1, 2 Check fuel trim system (See page DI−51). 3 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−45 DIAGNOSTICS 3 − ENGINE Check the output voltage of heated oxygen sensor (bank 1 sensor 1) during idling. PREPARATION: Warm up the heated oxygen sensor (bank 1 sensor 1) with the engine at 2,500 rpm for approx. 90 sec. CHECK: Use the OBD II scan tool or TOYOTA hand−held tester read the output voltage of the heated oxygen sensor (bank 1 sensor 1) during idling. OK: Heated oxygen sensor (bank 1 sensor 1) output voltage: Alternates repeatedly between less than 0.4 V and more than 0.55 V (See the Following table). P18349 OK Perform confirmation driving pattern (See page DI−43). NG Replace heated oxygen sensor (bank 1 sensor 1). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−46 DIAGNOSTICS − ENGINE DI5PB−02 DTC P0133 Heated Oxygen Sensor Circuit Slow Response (Bank 1 Sensor 1) CIRCUIT DESCRIPTION Refer to DTC P0125 (Insufficient Coolant Temp. for Closed Loop Fuel Control) on page DI−40. DTC No. P0133 DTC Detecting Condition Trouble Area Response time for the heated oxygen sensor’s voltage output to change from rich to lean, or from lean to rich, is 1 sec. or more during idling after the engine is warmed up (2 trip detection logic) S Heated oxygen sensor (bank 1 sensor 1) HINT: Sensor 1 refers to the sensor closer to the engine body. INSPECTION PROCEDURE 1 Are there any other codes (besides DTC P0133) being output? YES Go to relevant DTC chart. NO Replace heated oxygen sensor (bank 1 sensor 1). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−47 DIAGNOSTICS − ENGINE DI5PC−02 DTC P0135 Heated Oxygen Sensor Heater Circuit Malfunction (Bank 1 Sensor 1) DTC P0141 Heated Oxygen Sensor Heater Circuit Malfunction (Bank 1 Sensor 2) CIRCUIT DESCRIPTION Refer to DTC P0125 (Insufficient Coolant Temp. for Closed Loop Fuel Control) on page DI−40. DTC No. DTC Detecting Condition Trouble Area When the heater operates, heater current exceeds 2 A (2 trip detection logic) P0135 P0141 Heater current of 0.25 A or less when the heater operates (2 trip detection logic) S Open or short in heater circuit of heated oxygen sensor S Heated oxygen sensor heater S ECM HINT: Sensor 1 refers to the sensor closer to the engine body. Sensor 2 refers to the sensor farther away from the engine body. S S WIRING DIAGRAM Refer to DTC P0125 (Insufficient Coolant Temp. for Closed Loop Fuel Control) on page DI−40 for WIRING DIAGRAM. INSPECTION PROCEDURE 1 Check voltage between terminals HT1, HT2 of ECM connector and body ground. ON (−) HT1 (+) BE6653 P24460 HT2 A00950 PREPARATION: (a) Remove instrument panel speaker No.1 panel (See page SF−65). (b) Turn ignition switch ON. CHECK: Measure voltage between terminals HT1, HT2 of ECM connector and body ground. HINT: S Connect terminal HT1 to bank 1 sensor 1. S Connect terminal HT2 to bank 1 sensor 2. OK: Voltage: 9 − 14 V OK Check and replace ECM (See page IN−28). NG 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−48 DIAGNOSTICS 2 − ENGINE Check resistance of heated oxygen sensor heater (See page SF−64). NG Replace heated oxygen sensor. OK Check and repair harness or connector between EFI main relay (Marking: EFI) and heated oxygen sensor (bank 1 sensor 1, 2) and ECM (See page IN−28). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−49 DIAGNOSTICS − ENGINE DI5PD−02 DTC P0136 Heated Oxygen Sensor Circuit Malfunction (Bank 1 Sensor 2) CIRCUIT DESCRIPTION Refer to DTC P0125 (Insufficient Coolant Temp. for Closed Loop Fuel Control) on page DI−40. DTC No. DTC Detecting Condition Trouble Area P0136 Voltage output of the heated oxygen sensor (bank 1 sensor 2) remains at 0.4 V or more or 0.5 V or less when the vehicle is driven at 40 km/h (25 mph) or more after the engine is warmed up. (2 trip detection logic). S Heated oxygen sensor (bank 1 sensor 2) HINT: Sensor 2 refers to the sensor farther away from the engine body. WIRING DIAGRAM Refer to DTC P0125 (Insufficient Coolant Temp. for Closed Loop Fuel Control) on page DI−40 for WIRING DIAGRAM. INSPECTION PROCEDURE 1 Are there any other codes (besides DTC P0136) being output? YES Go to relevant DTC chart. NO 2 Check for open and short in harness and connector between ECM and heated oxygen sensor (bank 1 sensor 2) (See page IN−28). NG Repair or replace harness or connector. OK 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−50 DIAGNOSTICS 3 − ENGINE Check the output voltage of heated oxygen sensor (bank 1 sensor 2). PREPARATION: (a) Remove the fuse cover on the instrument panel. (b) Connect the OBD II scan tool or TOYOTA hand−held tester to the DLC3. (c) Warm up engine to normal operating temp. CHECK: Read voltage output of heated oxygen sensor (bank 1 sensor 2) when engine suddenly raced. HINT: Perform quick racing to 4,000 rpm 3 min. using accelerator pedal. OK: Heated oxygen sensor output voltage: Alternates from 0.4 V or less to 0.5 V or more. OK Check that each connector is properly connected. NG Replace heated oxygen sensor (bank 1 sensor 2). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−51 DIAGNOSTICS − ENGINE DI5PE−02 DTC P0171 System too Lean (Fuel Trim) DTC P0172 System too Rich (Fuel Trim) CIRCUIT DESCRIPTION ”Fuel trim” refers to the feedback compensation value compared against the basic injection time. Fuel trim includes short−term fuel trim and long−term fuel trim. ”Short−term fuel trim” is the short−term fuel compensation used to maintain the air−fuel ratio at its ideal theoretical value. The signal from the heated oxygen sensor indicates whether the air−fuel ratio is RICH or LEAN compared to the ideal theoretical value, triggering a reduction in fuel volume if the air−fuel ratio is rich, and an increase in fuel volume if it is lean. ”Long−term fuel trim” is overall fuel compensation carried out long−term to compensate for continual deviation of the short−term fuel trim form the central value due to individual engine differences, wear over time and changes in the usage environment. If both the short−term fuel trim and long−term fuel trim are LEAN or RICH beyond a certain value, it is detected as a malfunction and the MIL lights up. DTC No. DTC Detecting Condition Trouble Area P0171 When the air fuel ratio feedback is stable after engine warming up, the fuel trim is considerably in error on the RICH side. (2 trip detection logic) S Air intake (hose loose) S Fuel line pressure S Injector blockage, leak S Heated oxygen sensor (bank 1 sensor 1) malfunction S Mass air flow meter S Engine coolant temp. sensor P0172 When the air fuel ratio feedback is stable after engine warming up, the fuel trim is considerably in error on the LEAN side. (2 trip detection logic) S Fuel line pressure S Injector blockage, leak S Heated oxygen sensor (bank 1 sensor 1) malfunction S Mass air flow meter S Engine coolant temp. sensor HINT: When the DTC P0171 is recorded, the actual air−fuel ratio is on the LEAN side. When DTC P0172 is recorded, the actual air−fuel ratio is on the RICH side. If the total of the short−term fuel trim value and long−term fuel trim value is within + 30 − − 35 %, the system is functioning normally. If the vehicle runs out of fuel, the air−fuel ratio is LEAN and DTC P0171 is recorded. The MIL then come on. S S S INSPECTION PROCEDURE 1 Check air induction system (See page SF−1). NG Repair or replace OK 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−52 DIAGNOSTICS 2 − ENGINE Check for heated oxygen sensor (bank 1 sensor 1) data. PREPARATION: (a) Remove the fuse cover on the instrument panel. (b) Connect the OBD II scan tool or TOYOTA hand−held tester to the DLC3. (c) Warm up engine to normal operating temperature. CHECK: Read the heated oxygen sensor (bank 1 sensor 1) output voltage and short−term fuel trim. RESULT: Pattern Heated oxygen sensor (bank 1 sensor 1) output voltage Short−term fuel trim 1 Lean condition (Changes at 0.55 V or less) Changes at about +20 % 2 Rich condition (Changes at 0.4 V or more) 3 Changes at about −20 % Except 1 and 2 3 Check for heated oxygen sensor (bank 1 sensor 1) (See page SF−64). 1, 2 3 Check fuel pressure (See page SF−6). NG Check and repair fuel pump, pressure regulator, fuel pipe line and filter (See page SF−1). OK 4 Check injector injection (See page SF−29). NG Replace injector. OK 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−53 DIAGNOSTICS 5 − ENGINE Check mass air flow meter and engine coolant temp. sensor (See page SF−40, SF−61). NG Repair or replace. OK 6 Check for spark and ignition (See page IG−1). NG Repair or replace. OK Check and replace ECM (See page IN−28). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−54 DIAGNOSTICS − ENGINE DI5PF−02 DTC P0300 Random/Multiple Cylinder Misfire Detected DTC P0301 Cylinder 1 Misfire Detected DTC P0302 Cylinder 2 Misfire Detected DTC P0303 Cylinder 3 Misfire Detected DTC P0304 Cylinder 4 Misfire Detected DTC P0305 Cylinder 5 Misfire Detected DTC P0306 Cylinder 6 Misfire Detected CIRCUIT DESCRIPTION Misfire: The ECM uses the crankshaft position sensor and camshaft position sensor to monitor changes in the crankshaft rotation for each cylinder. The ECM counts the number of times the engine speed change rate indicates that misfire has occurred. When the misfire rate equals or exceeds the count indicating that the engine condition has deteriorated, the MIL lights up. If the misfire rate is high enough and the driving conditions will cause catalyst overheating, the MIL blinks when misfiring occurs. DTC No. DTC Detecting Condition P0300 Misfiring of random cylinders is detected during the any particular 200 or 1,000 revolutions P0301 P0302 P0303 P0304 P0305 P0306 For any particular 200 revolutions of the engine, misfiring is detected which can cause catalyst overheating (This causes MIL to blink) For any particular 1,000 revolutions of the engine, misfiring is detected which causes a deterioration in emission (2 trip detection logic) Trouble Area S Ignition system S Injector S Fuel line pressure S EGR S Compression pressure S Valve clearance not to specification S Valve timing S Mass air flow meter S Engine coolant temp. sensor HINT: When the 2 or more codes for a misfiring cylinder are recorded repeatedly but no random misfire code is recorded, it indicates that the misfires were detected and recorded at different times. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−55 DIAGNOSTICS − ENGINE WIRING DIAGRAM ECM W−R 3 EA2 Injector B−R 2 1 W−L W−R 11 IG Switch FL AM2 1 F7 6 Fusible Link B−R 14 IH1 No.1 B−R 2 No.2 B−R 2 B−R 1 W−R 1 W−G No.3 B−R2 B−R 2 B−R 2 1 Y 1 Y−R 1 Y−L No.4 No.5 No.6 BR BR Battery 12 #10 E4 11 #20 E4 25 #30 E4 2 #40 E4 1 E4 15 E4 13 E4 26 E4 #50 #60 E01 E02 EC P22424 Reference INSPECTION USING OSCILLOSCOPE INJECTOR SIGNAL WAVEFORM With the engine idling, measure between terminals #10 − #60 and E01 of ECM. HINT: The correct waveform is as shown. (Magnification) 10V/ Division 10V/ Division GND GND 100 m sec./Division (Idling) FI6588 FI6538 1 m sec./Division (Idling) Injection duration A00064 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−56 DIAGNOSTICS − ENGINE INSPECTION PROCEDURE 1 Check spark plug and spark of misfiring cylinder. P03792 P22893 A00164 PREPARATION: (a) Remove No.2 and No.3 cylinder head cover. (b) Disconnect the high−tension cord from spark plug. (c) Remove spark plug. CHECK: (a) Check the carbon deposits on electrode. (b) Check electrode gap. OK: (1) No large carbon deposit present. Not wet with gasoline or oil. (2) Electrode gap: 0.8 mm (0.031 in.). PREPARATION: (a) Install the spark plug to the high−tension cord. (b) Ground the spark plug. (c) Disconnect injector connector. CHECK: Check if spark occurs while engine is being cranked. NOTICE: To prevent excess fuel being injected from the injectors during this test, don’t crank the engine for more than 5 − 10 seconds at a time. OK: Spark jumps across electrode gap. NG Replace or check ignition system (See page IG−1). OK 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−57 DIAGNOSTICS 2 − ENGINE Check voltage of ECM terminal for injector of failed cylinder. ON #10 #20 #40 #50 #30 #60 BE6653 P24661 A00165 PREPARATION: (a) Remove instrument panel speaker No.1 panel (See page SF−65). (b) Turn ignition switch ON. CHECK: Measure voltage between applicable terminal of ECM connector and body ground. OK: Voltage: 9 − 14 V OK Go to step 4. NG 3 Check injector of misfiring cylinder (See page SF−29). NG Replace injector. OK Check for open and short in harness and connector between injector and ECM (See page IN−28). 4 Check fuel pressure (See page SF−6). NG Check and repair fuel pump, pressure regulator, fuel pipe line and filter (See page SF−1). OK 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−58 DIAGNOSTICS 5 − ENGINE Check injector injection (See page SF−29). NG Replace injector. OK 6 Check EGR system (See page EC−11). NG Repair EGR system. OK 7 Check mass air flow meter and engine coolant temp. sensor (See page SF−40, SF−61). NG Repair or replace. OK Check engine mechanical systems compression pressure (See page EM−3), valve clearance (See page EM−4) and valve timing (See page EM−13). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−59 DIAGNOSTICS − ENGINE DI5PG−02 DTC P0325 Knock Sensor 1 Circuit Malfunction DTC P0330 Knock Sensor 2 Circuit Malfunction CIRCUIT DESCRIPTION Knock sensors are fitted one each to the front and rear of the left side of the cylinder block to detect engine knocking. This sensor contains a piezoelectric element which generates a voltage when it becomes deformed, which occurs when the cylinder block vibrates due to knocking. If engine knocking occurs, ignition timing is retarded to suppress it. DTC No. DTC Detecting Condition Trouble Area P0325 No knock sensor 1 signal to ECM with engine speed, between 1,800 rpm and 5.200 rpm S Open or short in knock sensor 1 circuit S Knock sensor 1 (looseness) S ECM P0330 No knock sensor 2 signal to ECM with engine speed, between 1,800 rpm and 5.200 rpm S Open or short in knock sensor 2 circuit S Knock sensor 2 (looseness) S ECM If the ECM detects the above DTCs, it operates the fail safe function in which the corrective retard angle value is set to the maximum value. WIRING DIAGRAM ECM Knock Sensor 1 (On front side) 1 B 6 E5 KNK1 E1 Knock Sensor 2 (On rear side) 1 L−W 14 E5 KNK2 E1 P22425 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−60 DIAGNOSTICS − ENGINE INSPECTION PROCEDURE HINT: DTC P0325 is for the knock sensor circuit on the front side. DTC P0330 is for the knock sensor circuit on the rear side. S S 1 Check continuity between terminal KNK1, KNK2 of ECM connector and body ground. OFF KNK 1 (+) (−) BE6053 P24662 E5 Connector KNK 2 A08533 PREPARATION: (a) Remove the instrument panel speaker No.1 panel (See page SF−65). (b) Disconnect the E5 connector of ECM. CHECK: Measure resistance between terminal KNK1, KNK2 of ECM connector and body ground. HINT: S Connect terminal KNK1 to knock sensor 1. S Connect terminal KNK2 to knock sensor 2. OK: Resistance: 1 MΩ or higher OK Go to step 3. NG 2 Check knock sensor (See page SF−62). NG Replace knock sensor. OK 3 Check for open and short in harness and connector between ECM and knock sensor (See page IN−28). NG Repair or replace harness or connector. OK 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−61 DIAGNOSTICS 4 − ENGINE Does malfunction disappear when a good knock sensor is installed? YES Replace knock sensor. NO Check and replace ECM (See page IN−28). Knock signal waveform 0.5V/ Division 0V Reference: INSPECTION USING OSCILLOSCOPE S With the engine racing (4,000 rpm) measure between terminals KNK1, KNK2 of ECM and body ground. HINT: The correct waveform is as shown. 5 m sec./Division 0.5V/ Division S 0V Spread the time on the horizontal axis, and confirm that period of the wave is 164 μ sec. (Normal mode vibration frequency of knock sensor: 6.1 kHz). HINT: If normal mode vibration frequency is not 6.1 kHz the sensor is malfunctioning. 200 sec./Division A00068 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−62 DIAGNOSTICS − ENGINE DI5PH−02 DTC P0335 Crankshaft Position Sensor ”A” Circuit Malfunction CIRCUIT DESCRIPTION The crankshaft position sensor (NE signal) consists of a signal plate and pick up coil. The NE signal plate has 24 teeth and is built into the distributor. When the camshaft rotates, the protrusion on the signal plate and the air gap on the pick up coil change, causing fluctuations in the magnetic field and generating an electromotive force in the pick up coil. The NE signal sensor generates 24 signals for every engine revolution. The ECM detects the standard crankshaft angle based on the G1, G2 signals, detects the actual crankshaft angle and the engine speed by the NE signals, and detects misfire by NE2 signals. DTC No. P0335 DTC Detecting Condition Trouble Area No crankshaft position sensor signal (NE signal) to ECM during cranking. (2 trip detection logic) No crankshaft position sensor signal (NE signal) to ECM with engine speed 550 rpm or more (2 trip detection logic) S Open or short in crankshaft position sensor circuit for NE signal. S Crankshaft position sensor for NE signal S Starter S ECM WIRING DIAGRAM 1 W 12 NE E6 2 R 11 G1 E6 3 G 10 G2 E6 4 L L 4 E6 NE2− BR 5 NE2 E6 L 6 G− E6 ECM Distributor 1 2 L Crankshaft Position Sensor E1 S06273 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−63 DIAGNOSTICS − ENGINE INSPECTION PROCEDURE 1 Check resistance of crankshaft position sensor for NE signal. 4 3 2 1 (−) (+) PREPARATION: Remove the distributor cap and disconnect distributor connector. CHECK: Measure resistance between terminals 1 and 4 of distributor connector. OK: Resistance P24663 G, NE signal waveforms G1 5V/DIV G2 Cold 185 − 275 Ω Hot 240 − 325 Ω ”Cold” is from −10°C (14F°) to 50°C (122°F) of engine coolant temperature sensor and ”Hot” is from 50°C (122°F) to 100°C (212°F). Reference: INSPECTION USING OSCILLOSCOPE During cranking or idling, check between terminals G1, G2, NE, NE2 and G− of ECM. HINT: The correct waveforms are as shown. NE NE2 20 m sec/Division (Idling) P23505 NG Replace distributor housing assembly. OK 2 Check for open and short in harness and connector between ECM and crankshaft position sensor for NE signal (See page IN−28). NG Repair or replace harness or connector. OK 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−64 DIAGNOSTICS 3 − ENGINE Check air gap (See page IG−1). NG Replace distributor housing assembly. OK Check and replace ECM (See page IN−28). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−65 DIAGNOSTICS − ENGINE DI5PI−02 DTC P0340 Camshaft Position Sensor Circuit Malfunction CIRCUIT DESCRIPTION The camshaft position sensors (G1 and G2 signals) consist of a signal plate and a pick up coil. The G1, G2, signal plates each have one tooth on the outer circumference and are built into the distributor. When the camshaft rotates, the protrusion on the signal plate and the air gap on the pick up coil change, causing fluctuations in the magnetic field and generating an electromotive force in the pick up coil. The ECM detects the standard crankshaft angle based on the G1, G2 signals, detects the actual crankshaft angle and engine speed by the NE signals, and detects misfire by NE2 signals. DTC No. DTC Detecting Condition Trouble Area No camshaft position sensor signal (G signal) to ECM with engine speed 550 rpm or more. P0340 S Open or short in camshaft position sensor circuit S Camshaft position sensor S ECM WIRING DIAGRAM Refer to DTC P0335 (Crankshaft Position Sensor ”A” Circuit Malfunction) on page DI−62 for the WIRING DIAGRAM. INSPECTION PROCEDURE 1 4 Check resistance of camshaft position sensor. 3 2 1 (−) (+) PREPARATION: Disconnect camshaft position sensor connector. CHECK: Measure resistance between terminals 2, 3 and 4 of distributor connector. OK: Resistance P24663 Cold 185 − 275 Ω Hot 240 − 325 Ω ”Cold” is from −10°C (14°F) to 50°C (122°F) of engine coolant temperature and "Hot" is from 50°C (122°F) to 100°C (212°F). Reference: INSPECTION USING OSCILLOSCOPE Refer to page DI−62 for Reference INSPECTION USING OSCILLOSCOPE. NG Replace distributor housing assembly. OK 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−66 DIAGNOSTICS 2 − ENGINE Check for open and short in harness and connector between ECM and camshaft position sensor (See page IN−28). NG Repair or replace harness or connector. NG Replace distributor housing assembly. OK 3 Check air gap (See page IG−1). OK Check and replace ECM (See page IN−28). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−67 DIAGNOSTICS − ENGINE DI5PJ−02 DTC P0385 Crankshaft Position Sensor ”B” Circuit Malfunction CIRCUIT DESCRIPTION The crankshaft position sensor (NE2 signal) consists of a signal plate and a pick up coil. The NE2 signal plate has 34 teeth and is mounted on the crankshaft. When the crankshaft rotates, the protrusion on the signal plate and the air gap on the pick up coil change, causing fluctuations in the magnetic field and generating an electromotive force in the pick up coil. The NE2 signal sensor generates 34 signals for every engine revolution. The ECM detects the standard crankshaft angle based on G1, G2 signals detects the actual crankshaft angle and the engine speed by NE signals, and detects misfire by NE2 signals. DTC No. P0385 DTC Detecting Condition Trouble Area No crankshaft position sensor signal (NE 2 signal) to ECM during cranking. (2 trip detection logic) No crankshaft position sensor signal (NE 2 signal) to ECM with engine speed 550 rpm or more. (2trip detection logic) S Open or short in crankshaft position sensor for NE2 signals. S Crankshaft position sensor for NE2 signal. S ECM WIRING DIAGRAM Refer to DTC 0335 (Crankshaft Position Sensor ”A” Circuit Malfunction) on page DI−62 for WIRING DIAGRAM. INSPECTION PROCEDURE 1 Check resistance of crankshaft position sensor for NE2 signal. PREPARATION: Disconnect crankshaft position sensor connector. CHECK: Measure resistance between terminals 1 and 2 of crankshaft position sensor connector. OK: Resistance P22894 P24664 A00167 Cold 1630 − 2740 Ω Hot 2065 − 3225 Ω ”Cold” is from −10°C (14°F) to 50°C (122°F) of engine coolant temperature and "Hot" is from 50°C (122°F) to 100°C (212°F). Reference: INSPECTION USING OSCILLOSCOPE Refer to page DI−62 for Reference INSPECTION USING OSCILLOSCOPE. NG Replace crankshaft position sensor. OK 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−68 DIAGNOSTICS 2 − ENGINE Check for open and short in harness and connector between ECM and crankshaft position sensor for NE2 signal (See page IN−28). NG Repair or replace harness or connector. OK 3 Inspect sensor installation and teeth of signal plate. NG Tighten the sensor. Replace signal plate. OK Check and replace ECM (See page IN−28). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−69 DIAGNOSTICS − ENGINE DI5PK−02 DTC P0401 Exhaust Gas Recirculation Flow Insufficient Detected CIRCUIT DESCRIPTION The EGR system recirculates exhaust gas, which is controlled to the proper quantity to suit the driving conditions, into the intake air mixture to slow down combustion, reduce the combustion temp. and reduce NOx emissions. The amount of EGR is regulated by the EGR vacuum modulator according to the engine load. If even one of the following conditions is fulfilled, the VSV is turned ON by a signal from the ECM. This results in atmospheric air acting on the EGR valve, closing the EGR valve and shutting off the exhaust gas (EGR cut−off). ECM VSV Under the following conditions, EGR is cut to maintain driveabilEGR ity. Valve Throttle S Before the engine is warmed up. EGR valve Vacuum S During deceleration (throttle valve closed). Exhaust Intake Air Modulator Gas S Light engine load (amount of intake air very small). Chamber P22417 S Engine racing. DTC No. P0401 DTC Detecting Condition Trouble Area After the engine is warmed up and run at 80 km/h (50 mph) for 3 to 5 minutes, the EGR gas temperature sensor value does not exceed 38°C (100.4°F) above the ambient air temperature. (2 trip detection logic) S EGR valve stuck closed S Short in VSV circuit for EGR S Open in EGR gas temp. sensor circuit S EGR hose disconnected S ECM WIRING DIAGRAM ECM B+ 7 R 1 Y−R EB1 3 4 1 2 2 EFI 2 R−Y 2 EFI Main Relay 2 2 Y−R 2 EZ1 Y Y 1 2 VSV for EGR 1 R/B No.2 EB 4 EZ1 L−W 3 E7 22 E4 MRLY EGR E01 EGR Gas Temp. Sensor 2 BR 2 R EA2 5V G−Y 19 E4 THG BR−B 9 E5 E2 E1 From Battery P22426 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−70 DIAGNOSTICS − ENGINE SYSTEM CHECK DRIVING PATTERN Vehicle Speed (6) (3) 70 − 90 km/h (43 − 56 mph) Idling IG SW OFF (4) (2) (1) (7) (5) Warm up 3 − 5 min. 2 min. 3 − 5 min. 2 min. Time P20769 (1) Connect the OBD II scan tool or TOYOTA hand−held tester to the DLC3. (2) Start and warm up the engine with all accessories switched OFF. (3) Run the vehicle at 70 − 90 km/h (43 − 56 mph) for 3 min. or more. (4) Idle the engine for about 2 min. (5) Stop at safe place and turn the ignition switch OFF. (6) Start the engine and do steps (3) and (4) again. (7) Check the ”READINESS TESTS” mode on the OBD II scan tool or TOYOTA hand−held tester. If ”COMPL” is displayed and the MIL does not light up, the system is normal. If ”INCMPL” is displayed and the MIL does not light up, run the vehicle again and check it. HINT: ”INCMPL” is displayed when either condition (a) or (b) exists. (a) The system check is incomplete. (b) There is a malfunction in the system. If there is a malfunction in the system, the MIL will light up after steps (2) to (6) above are done. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−71 DIAGNOSTICS − ENGINE INSPECTION PROCEDURE TOYOTA hand−held tester 1 Connect the TOYOTA hand−held tester and read value of EGR gas temp. value. PREPARATION: (a) Remove the fuse cover on the instrument panel. (b) Connect the TOYOTA hand−held tester to the DLC3. (c) Turn ignition switch ON and push the TOYOTA hand−held tester main switch ON. CHECK: Read EGR gas temp. on the TOYOTA hand−held tester. OK: EGR gas temp.: 10°C (50°F) or more HINT: If there is and open circuit, the TOYOTA hand−held tester indicates 3.1°C (37.6°F). OK Go to step 4. NG 2 Check for open in harness or ECM. ON EGR Gas Temp. Sensor ECM 1 19 THG E4 9 2 BE6653 FI7055 5V E5 E2 PREPARATION: (a) Disconnect the EGR gas temp. sensor connector. (b) Connect sensor wire harness terminals together. (c) Turn ignition switch ON. CHECK: Read EGR gas temp. on the TOYOTA hand−held tester. OK: EGR gas temp.: Approx. 157.5°C (315.5°F) A00168 OK Confirm good connection at sensor. If OK, replace EGR gas temp. sensor. NG 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−72 DIAGNOSTICS 3 − ENGINE Check for open in harness or ECM. PREPARATION: (a) Remove the instrument panel speaker No.1 panel (See page SF−65). (b) Connect between terminals THG and E2 of ECM connector. HINT: EGR gas temp. sensor connector is disconnected. Before checking, do a visual check and contact pressure check for the ECM connector (See page IN−28). CHECK: Read EGR gas temp. on the TOYOTA hand−held tester. OK: EGR gas temp.: Approx. 157.5°C (315.5°F) ON EGR Gas Temp. Sensor 1 ECM 19 THG E4 9 2 THG 5V E5 E2 E2 BE6653 FI7057 P22167 A00169 OK Open in harness between terminals E2 or THG. Repair or replace harness. NG Confirm connection at ECM. If OK, replace ECM (See page IN−28). 4 Check the connection of the vacuum hose, EGR hose (See page EC−11). NG Repair or replace. OK 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−73 DIAGNOSTICS 5 − ENGINE Check the VSV for EGR. PREPARATION: (a) Remove the fuse cover on the instrument panel. (b) Connect the TOYOTA hand−held tester to the DLC3. (c) Turn ignition switch ON and TOYOTA hand−held tester main switch ON. (d) Select the ACTIVE TEST mode on the TOYOTA hand− held tester. CHECK: Check operation of VSV, when it is operated by the TOYOTA hand−held tester. OK: EGR system is ON: Air does not flow from pipe G to pipe E. EGR system is OFF: Air from pipe G is flowing out through pipe E. System : ON E Air G System : OFF E Air G P22963 P22964 A00170 OK Go to step 7. NG 6 Check operation of the VSV for EGR (See page SF−60). NG Replace VSV for EGR. OK Check for open in harness and connector between VSV and ECM (See page IN−28). 7 Check EGR vacuum modulator (See page EC−11). NG Repair or replace. OK 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−74 DIAGNOSTICS 8 − ENGINE Check EGR valve (See page EC−11). NG Repair or replace. OK 9 Check value of EGR gas temp. sensor. PREPARATION: (a) Remove the fuse cover on the instrument panel. (b) Connect the TOYOTA hand−held tester to the DLC3. (c) Turn ignition switch ON and TOYOTA hand−held tester main switch ON. (d) Select the ACTIVE TEST mode on the TOYOTA hand−held tester. (EGR system ON) (e) Race the engine at 4,000 rpm for 3 mins. CHECK: Measure the EGR gas temp. while racing engine at 4,000 rpm. OK: EGR gas temp. after 3 mins.: 140°C (284°F) or more NG Replace EGR gas temp. sensor. OK Check and replace ECM (See page IN−28). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−75 DIAGNOSTICS − ENGINE OBD II scan tool (excluding TOYOTA hand−held tester) 1 Check resistance of EGR gas temp. sensor. P24665 PREPARATION: Disconnect EGR gas temp. sensor connector. CHECK: Measure resistance between terminals of EGR gas temp. sensor connector. OK: Resistance: 600 kΩ or less HINT: If there is open circuit, ohmmeter indicates 720 kΩ or more. NG Check and replace EGR gas temp. sensor (See page SF−63). OK 2 Check for open in harness or ECM. ON (−) BE6653 P22896 P24666 (+) PREPARATION: (a) Disconnect EGR gas temp. sensor connector. (b) Turn ignition switch ON. CHECK: Measure voltage between terminals of EGR gas temp. sensor wire harness side connector. OK: Voltage: 4.5 − 5.5 V A00171 OK Go to step 4. NG 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−76 DIAGNOSTICS 3 − ENGINE Check for open in harness or ECM. PREPARATION: (a) Remove instrument panel speaker No.1 panel (See page SF−65). (b) Turn ignition switch ON. CHECK: Measure voltage between terminals of THG and E2 of ECM connector. HINT: EGR gas temp. sensor connector is disconnected. OK: Voltage: 4.5 − 5.5 V ON THG (+) (−) E2 BE6653 P24667 A00172 OK Open in harness between terminals E2 or THG. Repair or replace harness. NG Confirm connection at ECM. If OK, replace ECM (See page IN−28). 4 Check connection of vacuum hose, EGR hose (See page EC−11). NG Repair or replace. OK 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−77 DIAGNOSTICS 5 − ENGINE Check the VSV for EGR. PREPARATION: (a) Remove instrument panel speaker No.1 panel (See page SF−65). (b) Turn ignition switch ON. CHECK: Check VSV function. (1) Connect between terminal EGR of ECM and body ground (ON). (2) Disconnect between terminal EGR of ECM and body ground (OFF). OK: (1) VSV is ON: Air does not flow from pipe G to pipe E. (2) VSV is OFF: Air from pipe G is flows out through pipe E. ON EGR ON OFF (1) VSV is ON: E Air G (2) VSV is OFF: E Air G BE6653 P22905 P22963 P22964 A00173 OK Go to step 7. NG 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−78 DIAGNOSTICS 6 − ENGINE Check operation for the VSV for EGR (See page SF−60). NG Replace VSV for EGR. OK Check for open in harness and connector between R/B No.2 and ECM (See page IN−28). 7 Check EGR vacuum modulator (See page EC−11). NG Repair or replace. OK 8 Check EGR valve (See page EC−11). NG Repair or replace. OK 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−79 DIAGNOSTICS 9 − ENGINE Check resistance of EGR gas temp. sensor (See page SF−63). P24665 PREPARATION: (a) Disconnect EGR gas temp. sensor connector. (b) Start the engine and warm it up. (c) Disconnect VSV connector for EGR. (d) Race the engine at 4,000 rpm or 3 mins. CHECK: Measure the resistance of the EGR gas temp. sensor while racing the engine at 4,000 rpm. OK: Resistance of EGR gas temp. sensor after 3 mins.: 4.3 kΩ or less HINT: At 20°C (68°F): 188.6 − 439.0 kΩ for resistance. NG Replace EGR gas temp. sensor. OK Check and replace ECM (See page IN−28). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−80 DIAGNOSTICS − ENGINE DI5PL−02 DTC P0402 Exhaust Gas Recirculation Flow Excessive Detected CIRCUIT DESCRIPTION Refer to DTC P0401 (Exhaust Gas Recirculation Flow Insufficient Detected) on page DI−69. DTC No. P0402 DTC Detecting Condition Trouble Area EGR gas temp. sensor value is high during EGR cut−off when engine is cold (Race engine at about 4,000 rpm without load so that vacuum is applied to port E) (2 trip detection logic) EGR valve is always open (2 trip detection logic) S EGR valve stuck open S EGR VSV open malfunction S Open in VSV circuit for EGR S Short in EGR gas temp. sensor circuit S ECM Refer to DTC P0401 (Exhaust Gas Recirculation Flow Insufficient Detected) for the System Check Driving Pattern and Wiring Diagram. INSPECTION PROCEDURE TOYOTA hand−held tester 1 Connect the TOYOTA hand−held tester and read EGR gas temp. value. PREPARATION: (a) Remove the fuse cover on the instrument panel. (b) Connect the TOYOTA hand−held tester to the DLC3. (c) Turn ignition switch ON and push the TOYOTA hand−held tester main switch ON. CHECK: Read EGR gas temp. on the TOYOTA hand−held tester. OK: EGR gas temp.: 150°C (302°F) or less (Not immediately after driving) HINT: If there is a short circuit, the TOYOTA hand−held tester indicates Approx. 157.5°C (315.5°F). OK Go to step 4. NG 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−81 DIAGNOSTICS 2 − ENGINE Check for short in harness and ECM. ON EGR Gas Temp. Sensor 1 ECM 5V 19THG E4 9 E2 2 PREPARATION: Disconnect the EGR gas temp. sensor connector. CHECK: Read EGR gas temp. on the TOYOTA hand−held tester. OK: EGR gas temp.: 3.1°C (37.6°F) E5 BE6653 FI7054 A00174 OK Replace EGR gas temp. sensor. NG 3 Check for short in harness or ECM. ON EGR Gas Temp. Sensor ECM 5V THG E2 BE6653 FI7099 P22261 PREPARATION: (a) Remove the instrument panel speaker No.1 panel. (See page SF−65). (b) Disconnect the E4 connector of ECM. HINT: EGR gas temp. sensor is disconnected. CHECK: Read EGR gas temp. on the TOYOTA hand−held tester. OK: EGR gas temp.: 3.1°C (37.6°F) E4 connector A00175 OK Repair or replace harness or connector. NG Check and replace ECM (See page IN−28). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−82 DIAGNOSTICS 4 − ENGINE Check the VSV for EGR (See page DI−69). OK Check EGR valve (See page EC−11). NG 5 Check operation of the VSV for EGR (See page SF−60). NG Replace VSV for EGR. OK Check for short in harness and connector between VSV and ECM (See page IN−28). OBD II scan tool (excluding TOYOTA hand−held tester) 1 Check resistance of EGR gas temp. sensor (See page DI−105). P24665 PREPARATION: Disconnect EGR gas temp. sensor connector. CHECK: Measure resistance between terminals of EGR gas temp. sensor connector. OK: Resistance: 2.5 kΩ or more (Not immediately after driving) HINT: If there is short circuit, ohmmeter indicates 200 Ω or less. NG Replace EGR gas temp. sensor. OK 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−83 DIAGNOSTICS 2 − ENGINE Check for short in harness and connector between EGR gas temp. sensor and ECM (See page IN−28). NG Repair or replace harness or connector. OK 3 Check the VSV for EGR (See page DI−69, step 5). OK Check EGR valve (See page EC−11). NG 4 Check operation of the VSV for EGR (See page SF−60). NG Replace VSV for EGR. OK 5 Check for short in harness and connector between VSV and ECM (See page IN−28). NG Repair or replace harness or connector. OK Check and replace ECM (See page IN−28). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−84 DIAGNOSTICS − ENGINE DI5PM−02 DTC P0420 Catalyst System Efficiency Below Threshold CIRCUIT DESCRIPTION The ECM compares the waveform of the oxygen sensor located before the catalyst with the waveform of the oxygen sensor located after the catalyst to determine whether or not catalyst performance has deteriorated. Air−fuel ratio feedback compensation keeps the waveform of the oxygen sensor before the catalyst repeatedly changing back and forth from rich to lean. If the catalyst is functioning normally, the waveform of the oxygen sensor after the catalyst switches back and forth between rich and lean much more slowly than the waveform of the oxygen sensor before the catalyst. But when both waveforms change at a similar rate, it indicates that catalyst performance has deteriorated. Waveform of Oxygen Sensor Before Catalyst Waveform of Oxygen Sensor After Catalyst Normal Catalyst P23431 DTC No. DTC Detecting Condition P0420 After the engine is warmed up and the vehicle driven for 6 mins. at 30 − 83 km/h (19 − 52 mph), the waveforms of the heated oxygen sensors, bank 1 sensor 1 and bank1 sensor 2, have the same amplitude Trouble Area S Front exhaust pipe (front catalyst) and rear TWC (rear catalyst) S Heated oxygen sensor 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−85 DIAGNOSTICS − ENGINE CONFIRMATION ENGINE RACING PATTERN Vehicle Speed (3) 50 − 65 km/h (31 − 40mph) Idling IG SW OFF (2) (1) Warmed up 5 − 10 mins. Time A00560 (1) Connect the OBDII scan tool or TOYOTA hand−held tester to the DLC 3. (2) Start and warm up the engine with all accessories switched OFF. (3) Run the vehicle at 50 − 65 km/h (31 − 40 mph) for 5 − 10 mins. HINT: If a malfunction exists, the MIL will light up during step (3). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−86 DIAGNOSTICS − ENGINE INSPECTION PROCEDURE 1 Are there any other codes (besides DTC P0420) being output? YES Go to relevant DTC chart. NO 2 Check heated oxygen sensor (bank 1 sensor 1) (See page SF−64). NG Repair or replace. OK 3 Check heated oxygen sensor (bank 1 sensor 2) (See page SF−64). NG Repair or replace. OK Replace front exhaust pipe (front catalyst) and rear TWC (rear catalyst) (See page EM−110). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−87 DIAGNOSTICS − ENGINE DI5PN−02 DTC P0500 Vehicle Speed Sensor Malfunction CIRCUIT DESCRIPTION The vehicle speed sensor outputs a 4 − pulse signal for every revolution of the rotor shaft, which is rotated by the transmission output shaft via the driven gear. After this signal is converted into a more precise rectangular wavefrom by the waveform shaping circuit inside the combination meter, it is then transmitted to the ECM. The ECM determines the vehicle speed based on the frequency of these pulse signals. 4−pulse No.1 Vehicle Speed Sensor 4−pulse ECM Combination Meter P22487 DTC No. P0500 DTC Detecting Condition Trouble Area No vehicle speed sensor signal to ECM under conditions (a) and (b): (2 trip detection logic) (a) Park/neutral position switch is OFF. (b) Vehicle is being driven. S Open or short in No.1 vehicle speed sensor circuit S No.1 vehicle speed sensor S Combination meter S ECM WIRING DIAGRAM ECM From Cruise Control ECU 5V Combination Meter 3 C13 L−W L−W 8 SPD E7 E1 P22473 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−88 DIAGNOSTICS − ENGINE INSPECTION PROCEDURE 1 Check operation of speedometer. CHECK: Drive the vehicle and check if the operation of the speedmeter in the combination meter is normal. HINT: The vehicle speed sensor is operating normally if the speedometer display is normal. NG Check speedometer circuit (See page BE−2). OK 2 Check voltage between terminal SPD of ECM connector and body ground. ON (+) BE6653 P24668 (−) SPD A00176 PREPARATION: (a) Remove instrument panel speaker No.1 panel (See page SF−65). (b) Disconnect cruise control ECU connector. (c) Shift the shift lever to neutral. (d) Jack up a rear wheels on one side. (e) Turn ignition switch ON. CHECK: Measure voltage between terminal SPD of ECM connector and body ground when the wheel is turned slowly. OK: Voltage is generated intermittently. 9 − 14 V 0 NG Turn the wheel Check and repair harness and connector between combination meter and ECM. OK Check and replace ECM (See page IN−28). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 AT7809 Brought to you by BirfMark DI−89 DIAGNOSTICS − ENGINE DI5PO−02 DTC P0505 Idle Control System Malfunction CIRCUIT DESCRIPTION Throttle Valve From Air Cleaner Signals Intake Air Chamber Valve Coils ECM To Cylinders Rotor Valve Shaft IAC Valve The step motor type IAC valve is located in front of the intake air chamber. Intake air bypassing the throttle valve is directed to the IAC valve through a passage. A step motor is built into the IAC valve. It consists of four coils, a magnetic rotor, valve shaft and valve. When current flows to the coils due to signals from the ECM, the rotor turns and moves the valve shaft forward or backward, changing the clearance between the valve and the valve seat. In this way the intake air volume bypassing the throttle valve is regulated, controlling the engine speed. There are 125 possible positions to which the valve can be opened. P22234 DTC No. P0505 DTC Detecting Condition Idle speed continues to vary greatly from the target speed (2 trip detection logic) Trouble Area S IAC valve is stuck or closed S Open or short in IAC valve circuit S Open or short in A /C signal circuit S Air intake (hose loose) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−90 DIAGNOSTICS − ENGINE WIRING DIAGRAM ECM B+ 7 R 1 Y−R 4 2 1 Y−R R/B No.2 3 EB1 2 1 6 3 IAC Valve R−G R−B 3 MRLY E7 7 ISC1 E4 6 ISC2 E4 G−Y 5 ISC3 E4 Y−L 4 ISC4 E4 E01 E01 E01 E01 2 BR 2 4 Y−R 2 EFI 2 Y−R 5 R−Y 2 EFI Main Relay 2 R EA2 EB From Battery P22474 A/C Switch OFF → ON (IAC Valve Open) ISC1 20 V/ Division ISC2 ISC3 Reference: INSPECTION USING OSCILLOSCOPE With the engine idling measure wavefoms between terminals ISC1, ISC2, ISC3, ISC4 and E01 of ECM when A/C switch ON or OFF. HINT: The correct waveforms are as shown. ISC4 10 msec./Division A/C Switch ON → OFF (IAC Valve Close) ISC1 ISC2 20 V/ Division ISC3 ISC4 FI6536 FI6537 10 msec./Division A00202 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−91 DIAGNOSTICS − ENGINE INSPECTION PROCEDURE 1 Check air induction system (See page SF−1). NG Repair or replace. OK 2 Check voltage terminals ISC1, ISC2, ISC3, ISC4, of ECM connector and body ground. ON ISC1 ISC3 ISC2 ISC4 (−) (+) E4 connector BE6653 P24669 A00178 PREPARATION: (a) Remove instrument panel speaker No.1 panel (See page SF−65). (b) Disconnect the E4 connector of ECM. (c) Turn ignition switch ON. CHECK: Measure voltage between terminals ISC1, ISC2, ISC3, ISC4 of ECM connector and body ground. OK: Voltage: 9 − 14 V OK Go to step 4. NG 3 Check IAC valve (See page SF−49). NG Replace IAC valve. OK Check for open and short in harness and co−nnector between EFI main relay (Marking:EFI) and IAC valve and ECM (See page IN−28). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−92 DIAGNOSTICS 4 − ENGINE Check operation of the IAC valve . PREPARATION: Remove IAC valve (See page SF−51). CHECK: (a) Connect the positive (+) leak from the battery to terminals 5 (B1) and 2 (B2), and the negative (−) lead to terminals 4 (S1), −1 (S2), −6 (S3), −3 (S4) in that order. (b) Connect the positive (+) lead from the battery to terminals 5 (B1) and 2 (B2), and the negative (−) lead to terminals 3 (S4), − 6 (S3), −1 (S2), − 4 (S1) in that order. OK: (1) The valve moves to close direction. (2) The valve moves to open direction. HINT: The ACTIVE TEST mode of the TOYOTA hand−held tester can be used to change the step of the IAC valve as desired. Close B1 S3 S4 S1 S2 B2 Battery Open B1 S1 S2 S3 S4 B2 P24670 P24671 Battery A00203 NG Repair or replace IAC valve. OK Check and replace ECM (See page IN−28). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−93 DIAGNOSTICS − ENGINE DI5PP−02 DTC P0510 Closed Throttle Position Switch Malfunction CIRCUIT DESCRIPTION Refer to DTC P0120 (Throttle/Pedal Position Sensor/Switch ”A” Circuit Malfunction) on page DI−35. DTC No. P0510 DTC Detecting Condition Trouble Area The closed throttle position switch does not turn ON or OFF even once when the vehicle is driven (2 trip detection logic) S Open or short in closed throttle position switch circuit S Closed throttle position switch S ECM HINT: After confirming DTC P0510 use the TOYOTA hand−held tester to confirm the closed throttle position switch signal from ”CURRENT DATA”. Throttle Valve Closed Throttle Position Switch Signal Malfunction Fully closed OFF Open circuit Fully open ON Short circuit WIRING DIAGRAM Refer to DTC P0120 (Throttle/Pedal Position Sensor/Switch ”A” Circuit Malfunction) on page DI−35 for WIRING DIAGRAM. INSPECTION PROCEDURE HINT: If DTCs P0110 (Intake Air Temp. Circuit Malfunction), P0115 (Engine Coolant Temp. Circuit Malfunction), P0120 (Throttle/Pedal Position Sensor/Switch ”A” Circuit Malfunction) are output simultaneously, E2 (Sensor Ground) may be open. TOYOTA hand−held tester 1 Connect the TOYOTA hand−held tester and read CTP switch signal. PREPARATION: (a) Remove the fuse cover on the instrument panel. (b) Connect OBD II scan tool or TOYOTA hand−held tester to the DLC3. (c) Turn ignition switch ON and OBD II scan tool or TOYOTA hand−held tester main switch ON. CHECK: Read CTP switch signal on TOYOTA hand−held tester. RESULT: Throttle Valve Closed Throttle Position Switch Signal Malfunction Fully closed OFF Open circuit: Go to step 2 Fully open ON Short circuit: Go to step 4 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−94 DIAGNOSTICS 2 − ENGINE Check for open in harness or ECM. PREPARATION: (a) Disconnect throttle position sensor connector. (b) Connect sensor wire harness terminals between terminals 1 and 2. (c) Turn ignition switch ON. CHECK: Read CTP switch signal on TOYOTA hand−held tester. OK: CTP switch signal: ON ON Throttle Position Sensor 4 3 2 1 1 E5 ECM VCC 5V 10 VTA E5 11 IDL E5 9 E2 E5 BE6653 FI7058 12V E1 A00486 OK Confirm good connection at sensor. If OK, replace throttle position sensor. NG 3 Check for open in harness or ECM. PREPARATION: (a) Remove instrument panel speaker No.1 panel (See page SF−65). (b) Connect between terminals IDL and E2 of ECM. HINT: Throttle position sensor connector is disconnected. Before checking, do a visual check and contact pressure check for connector (See page IN−28). (c) Turn ignition switch ON. CHECK: Read CTP switch signal on TOYOTA hand−held tester. OK: CTP switch signal: ON ON Throttle Position Sensor 4 3 2 1 IDL FI7064 1 E5 ECM VCC 10 VTA E5 11 IDL E5 9 E2 E5 5V 12V E1 E2 A00487 OK Open in harness between ECM and throttle position sensor, repair or replace harness. NG Confirm connection at ECM. If OK, replace ECM (See page IN−28). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−95 DIAGNOSTICS 4 − ENGINE Check for short in harness or ECM. PREPARATION: (a) Disconnect throttle position sensor connector. (b) Turn ignition switch ON. CHECK: Read CTP switch signal on TOYOTA hand−held tester. OK: CTP switch signal: OFF ON ECM Throttle Position Sensor 4 1 VCC E5 3 2 1 5V 12V 10 VTA E5 11 IDL1 E5 9 E5 E2 E1 BE6653 A00499 A00488 OK Confirm good connection at sensor. If OK, replace throttle position sensor. NG 5 Check for short in harness or ECM. PREPARATION: (a) Remove instrument panel speaker No.1 panel (See page SF−65). (b) Disconnect E5 connector of ECM. HINT: Throttle position sensor connector is disconnected. (c) Turn ignition switch ON. CHECK: Read CTP switch signal on TOYOTA hand−held tester. OK: CTP switch signal: OFF ON Throttle Position Sensor 4 3 2 1 BE6653 A00498 A00496 ECM 1 VCC E5 10 VTA1 E5 11 E5 9 E5 5V 12V IDL1 E2 E5 Connector A00489 OK Short in harness between ECM and throttle position sensor, repair or replace harness. NG Confirm connection at ECM. If OK, replace ECM (See page IN−28). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−96 DIAGNOSTICS − ENGINE OBD II scan tool (excluding TOYOTA hand−held tester) 1 Check for open and short in harness or ECM. PREPARATION: (a) Disconnect throttle position sensor connector. (b) Turn ignition switch ON. CHECK: Measure voltage between terminals 1 and 2 of throttle position sensor connector. OK: Voltage: 9 − 14 V ON Throttle Position Sensor 4 3 2 1 ECM 1 E5 VCC 10 E5 11 E5 9 E5 5V 12V VTA IDL E2 E1 A00492 OK Confirm good connection at sensor. If OK, replace throttle position sensor. NG 2 Check for open and short in harness and connector between throttle position sensor and ECM (See page IN−28). NG Open or short in harness between ECM and throttle position sensor. OK Confirm connection at ECM. If OK, replace ECM (See page IN−28). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−97 DIAGNOSTICS − ENGINE DI5PQ−02 DTC P1300 Igniter Circuit Malfunction CIRCUIT DESCRIPTION The ECM determines the ignition timing, turns on Tr1 at a predetermined angle (°CA) before the desired ignition timing and outputs and ignition signal (IGT) ”1” to the igniter. Since the width of the IGT signal is constant, the dwell angle control circuit in the igniter determines the time the control circuit starts primary current flow to the ignition coil based on the engine rpm and ignition timing one revolution ago, that is, the time the Tr2 turns on. When it reaches the ignition timing, the ECM turns Tr1 off and outputs the IGT signal ”O”. This turns Tr2 off, interrupting the primary current flow and generating a high voltage in the secondary coil which causes the spark plug to spark. Also, by the counter electromotive force generated when the primary current is interrupted, the igniter sends an ignition confirmation signal (IGF) to the ECM. The ECM stops fuel injection as a fail safe function when the IGF signal is not input to the ECM. DTC No. DTC Detecting Condition Trouble Area No IGF signal to ECM for 6 consecutive IGT signals during engine running P1300 S Open or short in IGF or IGT circuit from igniter to ECM S Igniter S ECM WIRING DIAGRAM 1 EA2 B−R EA2 FL AM2 1 F7 Fusible Link Battery 1 5V Distributor 2 B−W 8 EA2 B−W W−B 2 Ignition Coil 4 IH1 W−B IG Switch W−R 3 ECM B−R 6 B−R W−R 11 1B Noise Filter 3 5 2 B−G 13 IH2 Tr2 4 1 B−Y 14 IH2 B−G 23 IGT E4 Tr1 17 B−Y E4 IGF Igniter EC P22475 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−98 DIAGNOSTICS − ENGINE INSPECTION PROCEDURE 1 Check for spark (See page IG−1). NG Go to step 4. OK 2 Check for open and short in harness and connector in IGF signal circuit between ECM and igniter (See page IN−28). NG Repair or replace harness or connector. OK 3 Disconnect igniter connector and check voltage between terminal IGF of ECM connector and body ground. ON (+) IGF BE6653 P24673 (−) A00183 PREPARATION: (a) Disconnect igniter connector. (b) Remove instrument panel speaker No.1 panel (See page SF−65). (c) Turn ignition switch ON. CHECK: Measure voltage between terminal IGF of ECM connector and body ground. OK: Voltage: 4.5 − 5.5 V OK Replace igniter. NG Check and replace ECM (See page IN−28). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−99 DIAGNOSTICS 4 − ENGINE Check for open and short in harness and connector in IGT signal circuit between ECM and igniter (See page IN−28). NG Repair or replace harness or connector. OK 5 Check voltage between terminals IGT of ECM connector and body ground. PREPARATION: Remove instrument panel speaker No.1 panel (See page SF−65). CHECK: Measure voltage between terminal IGT of ECM connector and body ground when engine is cranked. OK: Voltage: More than 0.1 V and less than 4.5 V START (+) IGT BE6653 P24674 (−) A00184 IGT signal waveform 2 V/Div. IGT 0V IGF Reference: INSPECTION USING OSCILLOSCOPE During cranking or idling, check waveforms between terminals IGT and E1 of engine control module. HINT: The correct regulator waveforms are as shown. 0V 5 m sec/Division (Idling) FI6605 NG Check and replace ECM (See page IN−28). NG 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−100 DIAGNOSTICS 6 ENGINE Disconnect igniter connector and check voltage between terminals IGT of ECM connector and body ground. START (+) IGT BE6653 P24674 − (−) A00184 PREPARATION: (a) Disconnect igniter connector. (b) Remove instrument panel speaker No.1 panel (See page SF−65). CHECK: Measure voltage between terminal IGT of ECM connector and body ground when engine is cranked. OK: Voltage: More than 0.1 V and less than 4.5 V OK Check and replace ECM (See page IN−28). NG 7 Check voltage between terminal 3 of igniter connector and body ground. PREPARATION: Disconnect igniter connector. CHECK: Measure voltage between terminal 3 of igniter connector and body ground, when ignition switch is turned to ”ON” and ”START” position. OK: Voltage: 9 − 14 V ON and START 3 BE6653 P24675 A00186 NG Check and repair igniter power source circuit. OK 8 Check for open and short in harness and connector between ignition switch and ignition coil, ignition coil and igniter (See page IN−28). NG Repair or replace harness or connector. OK 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−101 DIAGNOSTICS 9 − ENGINE Check ignition coil (See page IG−1). NG Replace ignition coil. OK Replace igniter. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−102 DIAGNOSTICS − ENGINE DI5PR−02 DTC P1335 Crankshaft Position Sensor Circuit Malfunction (during engine running) CIRCUIT DESCRIPTION Refer to DTC P0335 (Crankshaft Position Sensor ”A” Circuit Malfunction) on page DI−62. DTC No. P1335 DTC Detecting Condition No crankshaft position sensor signal (NE signal) to ECM with engine speed 1,000 rpm or more Trouble Area S Open or short in crankshaft position sensor circuit for NE signal S Crankshaft position sensor for NE signal S Starter S ECM WIRING DIAGRAM See DTC P0335 (Crankshaft Position Sensor ”A” Circuit Malfunction) for WIRING DIAGRAM and INSPECTION PROCEDURE. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−103 DIAGNOSTICS − ENGINE DI968−01 DTC P1500 Starter Signal Circuit Malfunction CIRCUIT DESCRIPTION When the engine is cranked, the intake air flow is slow, so fuel vaporization is poor. A rich mixture is therefore necessary in order to achieve good startability. While the engine is being cranked, the battery positive voltage is applied to terminal STA of the ECM. The starter signal is mainly used to increase the fuel injection volume for the starting injection control and after−start injection control. WIRING DIAGRAM A15825 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−104 DIAGNOSTICS − ENGINE INSPECTION PROCEDURE HINT: This diagnostic chart is based on the premise that the engine is cranked normally. If the engine is not cranked, proceed to the matrix chart of problem symptoms on page DI−19. 1 Connect TOYOTA hand−held tester and check STA signal. PREPARATION: (a) Connect the TOYOTA hand−held tester to the DLC3. (b) Turn ignition switch ON and push TOYOTA hand−held tester main switch ON. CHECK: Read STA signal on the TOYOTA hand−held tester while starter operates. OK: Ignition Switch Position ON START STA Signal OFF ON OK Proceed to next circuit inspection shown on matrix chart (See page DI−19). NG 2 Check for open in harness and connector between ECM and starter relay (See page IN−28). NG Repair or replace harness or connector. OK Check and replace ECM (See page IN−28). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−105 DIAGNOSTICS − ENGINE DI5PT−02 DTC P1600 ECM BATT Malfunction CIRCUIT DESCRIPTION Battery positive voltage is supplied to terminal BATT of the ECM even when the ignition switch is OFF for use by the DTC memory and air−fuel ratio adaptive control value memory, etc. DTC No. P1600 DTC Detecting Condition Trouble Area S Open in back up power source circuit S ECM Open in back up power source circuit HINT: If DTC P1600 appear, the ECM does not store another DTC. WIRING DIAGRAM ECM R/B No.2 W 2 EFI 2 R−Y 2 EA2 R−Y 2 E7 BATT FL MAIN 1 E8 Fusible Link Battery P22477 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−106 DIAGNOSTICS − ENGINE INSPECTION PROCEDURE 1 Check voltage between terminal BATT of ECM connector and body ground. LOCK BATT (+) (−) BE6053 P24676 PREPARATION: Remove the instrument panel speaker No.1 panel (See page SF−65). CHECK: Measure voltage between terminal BATT of ECM connector and body ground. OK: Voltage 9 − 14 V A08534 OK Check and replace ECM (See page IN−28). NG 2 Check EFI fuse. PREPARATION: Remove EFI fuse from R/B No.2. CHECK: Check continuity of EFI fuse. OK: Continuity EFI Fuse R/B No.2 P22346 NG Check for short in all the harness and components connected to EFI fuse. OK Check and repair harness or connector between battery, EFI fuse and ECM. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−107 DIAGNOSTICS − ENGINE DI5PU−02 DTC P1605 Knock Control CPU Malfunction CIRCUIT DESCRIPTION Refer to DTC P0325, P0330 (Knock Sensor 1, 2 Circuit Malfunction) on page DI−59. DTC No. P1605 DTC Detecting Condition Trouble Area Engine control computer malfunction (for knock control) S ECM WIRING DIAGRAM Refer to P0325, P0330 (Knock Sensor 1, 2 Circuit Malfunction) on page DI−59. INSPECTION PROCEDURE 1 Are there any other codes (besides DTC P1605) being output? YES Go to relevant DTC chart. NO Check and replace ECM (See page IN−28). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−108 DIAGNOSTICS − ENGINE DI5PV−02 DTC P1780 Park/Neutral Position Switch Malfunction CIRCUIT DESCRIPTION The park/neutral position switch goes on when the shift lever is in the N or P shift position. When it goes on terminal NSW of the ECM is grounded to body ground via the starter relay, thus the terminal NSW voltage becomes 0 V. When the shift lever is in the D, 2, L or R position, the park/neutral position switch goes off, so the voltage of ECM, terminal NSW becomes battery voltage, the voltage of the ECM internal power source. If the shift lever is moved from the N position to the D position, this signal is used for air−fuel ratio correction and for idle speed control (estimated control), etc. DTC No. DTC Detecting Condition Trouble Area 2 or more switches are ON simultaneously for ”N”, ”2” and ”L” position (2 trip detection logic) S Short in park/neutral position switch circuit S Park/neutral position switch S ECM When driving under conditions (a) and (b) for 30 sec. or more the park/neutral position switch is ON (N position): (2 trip detection logic) (a) Vehicle speed: 70 km/h (44 mph) or more (b) Engine speed: 1,500 − 2,500 rpm P1780 HINT: After confirming DTC P1780 use the TOYOTA hand−held tester to confirm the PNP switch signal from ”CURRENT DATA”. WIRING DIAGRAM 2 B Y 4 2 G−R ECM 2 IH2 3 IH2 G−W 17 L E7 O 16 2 E7 E1 Y 2 B 6 EA2 FL AM1 1 F6 Fusible Link B−L 2 6 IH1 4 To A/T Indicator Light (Combination Meter) GAUGE 4 Fuse Block AM1 3 R/B No.2 2 2 Junction Connector (J4) Y B B Park/Neutral Position Switch 3 O 1 B−W IG Switch 21 IH1 6 B−W 5 B−R 1 S1 B+ Starter Battery E1 B−Y W B−W 22 NSW E7 E1 P22478 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−109 DIAGNOSTICS − ENGINE INSPECTION PROCEDURE 1 Check park/neutral position switch. 4 10 3 9 1 2 8 PREPARATION: Disconnect park/neutral position switch connector. CHECK: Check continuity between each terminal shown below when the shift lever is positioned to each range. OK: 6 5 7 Shift Position Terminal No. to continuity Terminal No. to continuity P 4−7 5−6 P24677 NG R 4−8 − N 4 − 10 5−6 D 4−9 − 2 2−4 − L 3−4 − Replace park/neutral position switch. OK 2 Check voltage between terminal NSW of ECM connector and body ground. ON (+) BE6653 P24678 (−) NSW A00188 PREPARATION: Remove instrument panel speaker No.1 panel (See page SF−65). CHECK: (a) Turn ignition switch ON. (b) Measure voltage between terminal NSW of ECM connector and body ground when the shift lever is positioned to the following positions. OK: Shift lever position P or N L, 2, D or R Voltage 0V 9 − 14 V OK Check and replace ECM (See page IN−28). NG Check for open and short in harness and connector between ECM and park/neutral position switch (See page IN−28). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−110 DIAGNOSTICS − ENGINE DI5PX−02 ECM Power Source Circuit CIRCUIT DESCRIPTION When the ignition switch is turned ON, battery positive voltage is applied to the coil, closing the contacts of the EFI main relay (Marking: EFI) and supplying power to the terminals +B of the ECM. WIRING DIAGRAM ECM B+ W−R 11 6 IG Switch 2 W−R W FL MAIN FL AM2 Fusible Link R 3 E7 MRLY Y 12 +B E7 2 EFI 2 1 F7 1 F8 IGSW IGN Fuse Block R −Y 2 EA2 1 E7 B−L 2 4 1 3 EFI Main Relay 2 Y−R R 2 1 7 EA2 EB1 R/B No.2 Y−R B−R 3 B−R 22 IH1 BR−B Battery EB 24 E4 E1 EC S00816 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−111 DIAGNOSTICS − ENGINE INSPECTION PROCEDURE 1 Check voltage between terminals +B and E1 of the ECM connector. ON E1 (−) BE6653 P24679 (+) +B A00189 PREPARATION: (a) Remove instrument panel speaker No.1 panel (See page SF−65). (b) Turn ignition switch ON. CHECK: Measure voltage between terminals +B and E1 of the ECM connector. OK: Voltage: 9 − 14 V OK Proceed to next circuit inspection shown on matrix chart (See page DI−19). NG 2 Check for open in harness and connector between terminal E1 of ECM connector and body ground (See page IN−28). NG Repair or replace harness or connector. OK 3 Check voltage between terminal IGSW of ECM connector and body ground. ON IGSW BE6653 P24680 (+) (−) A00190 PREPARATION: (a) Remove instrument panel speaker No.1 panel (See page SF−65). (b) Turn ignition switch ON. CHECK: Measure voltage between terminals IGSW of ECM and body ground. OK: Voltage: 9 − 14 V OK Go to step 6. NG 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−112 DIAGNOSTICS 4 − ENGINE Check IGN fuse from fuse block. NG Check for short in all the harness and components connected to IGN fuse. OK 5 Check ignition switch. PREPARATION: (a) Remove instrument lower finish panel. (b) Remove instrument cluster finish center panel No.2. CHECK: Check continuity between terminals. OK: Shift Position P24681 NG Terminal No. to continuity Terminal No. to continuity LOCK − − ACC 3−4 − ON 2−3−4 6 − 11 START 1−2−4 5 − 6 − 11 Replace ignition switch. OK Check for open and short in harness and connector between battery and ignition switch and ECM. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−113 DIAGNOSTICS 6 − ENGINE Check voltage between terminal MREL of ECM connector and body ground. ON (+) MRLY (−) BE6653 P24682 A00191 PREPARATION: (a) Remove instrument panel speaker No.1 panel (See page SF−65). (b) Turn ignition switch ON. CHECK: Measure voltage between terminal MREL of ECM and body ground. OK: Voltage: 9 − 14 V NG Check and replace ECM. OK 7 Check EFI fuse (Marking: EFI) (See page DI−105). NG Check for short in all the harness and components connected to EFI fuse. OK 8 Check EFI main relay (Marking: EFI) (See page SF−54). NG Replace EFI main relay (Marking: EFI). OK 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−114 DIAGNOSTICS 9 − ENGINE Check for open and short in harness and connector between terminal MREL of ECM connector and body ground (See page IN−28). NG Repair or replace harness or connector. OK Check for open and short in harness and connector between terminal +B of ECM connector and battery (See page IN−28). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−115 DIAGNOSTICS − ENGINE DI5PY−02 Fuel Pump Control Circuit CIRCUIT DESCRIPTION In the diagram below, when the engine is cranked, current flows form terminal ST of the ignition switch to terminal STA of ECM (STA signal). When the STA signal and NE signal are input to the ECM, Tr1 is turned ON, current flows to coil of the circuit opening relay, the relay switches on, power is supplied to the fuel pump and the fuel pump operates. While the NE signal is generated (engine running), the ECM keeps Tr1 ON (circuit opening relay ON) and the fuel pump also keeps operating. The fuel pump speed is controlled at 2 levels (high speed or low speed) by the condition of the engine (starting, light load, heavy load). When the engine starts (STA ON), Tr2 in the ECM is OFF, so battery voltage is applied directry to the fuel pump. Fuel pump operates at high speed. After the engine starts, during idling or light loads, since Tr2 goes ON, power is supplied to the fuel pump via the fuel pump resistor. Fuel pump operates at low speed. EFI Main Relay Circuit Opening Relay FL AM2 EFI FL MAIN ECM MRLY Fuel Pump Relay FPR IG Switch IG IGN ST Tr2 Fuel Pump Resistor Park/ N eut ra l Position Switch Fuel Pump FC (STA Signal) Tr1 STA Battery Starter (NE Signal) From Crankshaft Position Sensor NE P22480 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−116 − DIAGNOSTICS ENGINE WIRING DIAGRAM ECM R−Y 2 2 B+ 1 4 FEI 2 1 3 BR 2 2 Y−R EB1 Y−R 7 R 2 EA2 3 R E7 MRLY EFI Main Relay 2 22 IH1 W−R R/B No.2 Circuit Opening Relay EB 4 R−G Y 2 W 11 6 B−R IG Switch R−W 5 IH1 R−W 14 E4 FC E01 Fuel Pump Relay EA2 3 2 1 3 Fusible Link BO1 13 R−G ID2 R−W R−B 1 R−B 2 Fuel Pump Resister R−G FL AM2 17 Fuse Block 1 E8 1 F7 FL MAIN 3 B−L IGN W−R 3 1 3 W−R 13 E7 FPR E01 5 6 BO1 W−B W−B Battery Fuel Pump BF S02978 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−117 DIAGNOSTICS − ENGINE INSPECTION PROCEDURE TOYOTA hand−held tester 1 Connect the TOYOTA hand−held tester and check operation of fuel pump. P09401 PREPARATION: (a) Remove the fuse cover on the instrument panel. (b) Connect the TOYOTA hand−held tester to the DLC3. (c) Turn ignition switch ON and TOYOTA hand−held tester main switch ON. (d) Use ACTIVE TEST mode to operate the fuel pump. CHECK: Check for fuel pressure in the fuel return hose when it is pinched off. OK: There is pressure in the fuel return hose. HINT: At this time, you will hear a fuel flowing noise. OK Go to step 4. NG 2 Check circuit opening relay (See page SF−56). NG Replace circuit opening relay. OK 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−118 DIAGNOSTICS 3 ENGINE Check voltage between terminal FC of ECM connector and body ground. ON (+) BE6653 P24684 − (−) FC A00192 PREPARATION: (a) Remove instrument panel speaker No.1 panel (See page SF−65). (b) Turn ignition switch ON. CHECK: Measure voltage between terminal FC of ECM and body ground. OK: Voltage: 9 − 14 V OK Go to step 5. NG Check for open and short in harness and connector between terminal FC of ECM and circuit opening relay and fuse block (See page IN−28). 4 Connect the TOYOTA hand−held tester and check operation of fuel pump relay. PREPARATION: (a) Connect the TOYOTA hand−held tester to the DLC3. (b) Start the engine. (c) Turn TOYOTA hand−held tester main switch ON. (d) Select the ACTIVE TEST mode on the TOYOTA hand−held tester. CHECK: Check operation of fuel pump relay when it is switched ON and OFF by the TOYOTA hand−held tester. OK: Operating noise can be heard from the relay. OK Go to step 8. NG 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−119 DIAGNOSTICS 5 − ENGINE Check operation of fuel pump relay. PREPARATION: (a) Disconnect fuel pump relay connector. (b) Remove fuel pump relay. CHECK: Check continuity between terminals of fuel pump relay. OK: Open 3 1 2 Continuity Continuity 6 4 5 (+) 3 (−) 2 Continuity Terminals 2 and 5 Open Terminals 1 and 5 Continuity (Reference value 80 Ω) CHECK: (a) Apply battery voltage between terminals 1 and 5. (b) Measure voltage between terminals 1 and 2. OK: 1 Open 6 Terminals 3 and 5 Terminals 1 and 2 4 Battery voltage 5 P24685 P24686 A00193 NG Replace fuel pump relay. OK 6 Check voltage between terminal FPR of ECM connector and body ground. (+) (−) FPR PREPARATION: (a) Remove instrument panel speaker No.1 panel (See page SF−65). (b) Start the engine. CHECK: Measure voltage between terminal FPR of ECM and body ground while racing the engine. OK: P24687 OK Time after engine started Voltage 60 seconds or more 0−3V Less than 60 seconds 9 − 14 V Check and replace ECM (See page IN−28). NG 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−120 DIAGNOSTICS 7 − ENGINE Check for open and short in harness and connector between terminal FPR of ECM connector and fuel pump relay (See page IN−28). NG Repair or replace harness or connector. OK 8 Check operation of fuel pump. High P22900 P09401 FPR Low PREPARATION: (a) Remove instrument panel speaker No.1 panel (See page SF−65). (b) Connect the TOYOTA hand − held tester to the DLC3. (c) Turn ignition switch ON and TOYOTA hand−held tester main switch ON. (d) Use ACTIVE TEST mode to operate the fuel pump. CHECK: Check operation of fuel pump, when it is operated by the TOYOTA hand−held tester and terminal FPR of ECM is grounded and is not grounded. OK: There is pressure in the inlet hose. HINT: At this time, you will hear a fuel flowing noise. FPR is grounded (Low speed) FPR is not grounded (High speed) NG NG Go to step 9 NG OK Go to step 10 NG Repair or replace harness or connector between fuel pump relay and fuel pump. A00194 OK 9 Check fuel pump (See page SF−6). NG Repair or replace fuel pump. OK Check for open or short in harness and connector between EFI main relay (Marking: EFI) and circuit opening relay and fuel pump relay and fuel pump and body ground (See page IN−28). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−121 DIAGNOSTICS 10 − ENGINE Check fuel pump resistor. (See page SF−58). NG Replace fuel pump resistor. OK Check for open and short in harness and connector between fuel pump relay and fuel pump resistor and fuel pump (See page IN−28). OBD II scan tool (excluding TOYOTA hand−held tester) 1 Check fuel pump operation. PREPARATION: (a) Remove instrument panel speaker No.1 panel (See page SF−65). (b) Turn ignition switch ON. CHECK: (a) Connect between terminal FC of ECM and body ground. (b) Check for fuel pressure in the fuel inlet hose when it is pinched off. OK: There is pressure in the fuel inlet hose. HINT: At this time, you will hear a fuel flowing noise. ON FC BE6653 P22178 P09401 A00195 OK Go to step 4. OK 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−122 DIAGNOSTICS 2 − ENGINE Check circuit opening relay (See page DI−84). NG Replace circuit opening relay. OK 3 Check voltage between terminal FC of ECM connector and body ground (See step 3 of TOYOTA hand−held tester). OK Go to step 4. NG Check for open and short in harness and connector between terminal FC of ECM and circuit opening relay and fuse block (See page IN−28). 4 Check operation of fuel pump relay (See step 5 of TOYOTA hand−held tester). NG Replace fuel pump relay. OK 5 Check voltage between terminal FPR of ECM connector and body ground (See step 6 of TOYOTA hand−held tester). NG 6 Check and replace ECM (See page IN−28). Check for open and short in harness and connector between terminal FC of ECM connector and fuel pump relay (See page IN−28). NG Repair or replace harness or connector. OK 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−123 DIAGNOSTICS 7 ENGINE Check operation of fuel pump. ON FC High BE6653 P22901 P09401 8 − FPR Low PREPARATION: (a) Remove instrument panel speaker No.1 panel (See page SF−65). (b) Turn ignition switch ON. CHECK: (a) Connect terminal FC of ECM and body ground. (b) Check operation of fuel pump when terminal FPR of ECM is grounded and is not grounded. OK: There is pressure in the inlet hose. HINT: At this time, you will hear a fuel flowing noise. FPR is grounded (Low speed) FPR is not grounded (High speed) NG NG Go to step 8 NG OK Go to step 9 NG Repair or replace harness or connecter between fuel pump relay and fuel pump. OK A00196 Check fuel pump (See page SF−6). NG Repair or replace fuel pump. OK Check for open or short in harness and connector between EFI main relay (Marking: EFI) and circuit opening relay and fuel pump relay and fuel pump and body ground (See page IN−28). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−124 DIAGNOSTICS 9 − ENGINE Check fuel pump resistor (See page SF−58). NG Replace fuel pump resistor. OK Check for open and short in harness and connector between fuel pump relay and fuel pump resistor and fuel pump (See page IN−28). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−125 DIAGNOSTICS − ENGINE DI5PZ−02 Fuel Pressure Control Circuit CIRCUIT DESCRIPTION Pressure Regulator VSV ECM To Fuel Tank (Return) Intake Manifold From Delivery Pipe P22216 The ECM turns on a VSV (Vacuum Switching Valve) to draw the air into the diaphragm chamber of the pressure regulator if it detects that the temperature of the engine coolant is too high during engine starting. The air drawn into the chamber increases the fuel pressure to prevent fuel vapor lock at high engine temperature in order to help the engine start when it is warm. Fuel pressure control ends approx. 120 sec. after the engine is started. WIRING DIAGRAM ECM B+ 7 R Y−R 2 2 2 EFI 2 1 R−Y 1 BR 2 EB Y−R R/B No.2 Relay 3 4 EFI Main 2 1 EB1 3 E7 MRLY R EA2 EZ1 B 2 1 B 3 EZ1 VSV for Fuel Pressure Control 21 L−R E4 FPU E01 2 From Battery P22482 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−126 DIAGNOSTICS − ENGINE INSPECTION PROCEDURE TOYOTA hand−held tester 1 Connect the TOYOTA hand−held tester and check operation of VSV for fuel pressure control. PREPARATION: (a) Remove the fuse cover on the instrument panel. (b) Connect the TOYOTA hand−held tester to the DLC3. (c) Turn ignition switch ON and TOYOTA hand−held tester main switch ON. (d) Select the ACTIVE TEST mode on the TOYOTA hand− held tester. CHECK: Check operation of VSV when VSV is operated by the TOYOTA hand−held tester. OK: VSV is ON: Air from pipe E is flowing out through the air filter. VSV is OFF: Air from pipe E is flowing out through pipe G. ON ON G E Air Filter OFF G BE6653 P22965 P22966 E Air Filter A00197 OK Check and repair fuel pressure regulator (See page SF−19). NG 2 Check VSV for fuel pressure control (See page SF−59). NG Replace VSV for fuel pressure control. OK 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−127 DIAGNOSTICS 3 − ENGINE Check for open and short in harness and connector between EFI main relay (Marking: EFI) and ECM (See page IN−28). NG Repair or replace harness or connector. OK Check and replace ECM (See page IN−28). OBD II scan tool (excluding TOYOTA hand−held tester) 1 Check VSV for fuel pressure control (See page SF−59). NG Replace VSV for fuel pressure control. OK 2 Check voltage between terminal FPU of ECM connector and body ground. ON (+) BE6653 P24688 (−) FPU A00198 PREPARATION: (a) Remove instrument panel speaker No.1 panel (See page SF−65). (b) Turn ignition switch ON. CHECK: Measure voltage between terminal FPU of ECM connector and body ground. OK: Voltage: 9 − 14 V NG Check for open and short in harness and connector between EFI main relay (Marking: EFI) and ECM (See page IN−28). OK 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−128 DIAGNOSTICS 3 − ENGINE Check fuel pressure regulator (See page SF−19). NG Repair or replace fuel pressure regulator. OK Check and replace ECM (See page IN−28). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−129 DIAGNOSTICS − AUTOMATIC TRANSMISSION AUTOMATIC TRANSMISSION DI5K4−03 HOW TO PROCEED WITH TROUBLESHOOTING Troubleshoot in accordance with the procedure on the following page. Items inside are titles of pages in this manual, with the page number indicated in the bottom portion. See the indicated pages for detailed explanations. Vehicle Brought to Workshop Step 2, 3, 4, 6, 9, 15, 18: Diagnostic steps permitting the use of the TOYOTA hand−held tester or TOYOTA brake−out−box. 1 Customer Problem Analysis 2 Connect an OBD II scan tool or TOYOTA hand−held tester to DLC3. If your display shows ”UNABLE TO CONNECT TO VEHICLE” when you have connected the scan tool/TOYOTA hand−held tester, inspect DLC3 DI−131 DI−130 3 Check DTC and Freezes Frame Data (Pre−check) Record or Print DTC and Freezed Frame Data DI−131 4 Clear DTC and Freezed Frame Data DI−131 5 Visual Inspection 6 Setting the Check Mode Diagnosis DI−131 symptom does not occur 8 7 Problem Symptom Confirmation Symptom Simulation P.IN−18 symptom occurs 9 DTC Check 10 DTC Chart DI−131 OK Code 11 Preliminary Check NG DI−131 OK 12 Mechanical System Tests NG DI−143 NG 13 DI−131 OK Manual Shifting Test NG DI−131 14 Matrix Chart of Problem Symptoms − DI−147 Chapter 1 (Electronic) Chapter 2 (On−Vehicle) OK DI−147 DI−147 NG 15 Circuit Inspection OK Chapter 3 (Off−Vehicle) DI−147 NG NG SStop Light Signal SO/D Cancel Signal Check 16 Parts Inspection DI−153 − DI−185 Identification of Problem 17 Repair 18 Confirmation Test End 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 296 Brought to you by BirfMark DI−130 − DIAGNOSTICS AUTOMATIC TRANSMISSION DI5K6−01 CUSTOMER PROBLEM ANALYSIS CHECK Transmission Control System Check Sheet Inspector’s Name : Registration No. Customer’s Name Registration Year / / Frame No. Date Vehicle Brought In / Date Problem Occurred How Often Does Problem Occur? / km mile Odometer Reading /  Continuous /  Intermittent (  Vehicle does not move (  Any position  No up−shift (  1st → 2nd  No down−shift (  O/D → 3rd times a day)  Particular position )  2nd → 3rd  3rd → 2nd  3rd → O/D )  2nd → 1st )  Lock−up malfunction Symptoms  Shift point too high or too low  Harsh engagement (  N → D  Lock−up  Any drive position )  Slip or shudder  No kick−down  Others Check Item Malfunction Indicator Lamp  Normal  Remains ON DTC Check 1st Time  Normal code  Malfunction code (Code ) 2nd Time  Normal code  Malfunction code (Code ) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−131 DIAGNOSTICS − AUTOMATIC TRANSMISSION PRE−CHECK 1. (a) DI5K9−03 DIAGNOSIS SYSTEM Description S When troubleshooting OBD II vehicles, the only difference from the usual troubleshooting procedure is that you connect to the vehicle the OBD II scan tool complying with SAE J1978 or TOYOTA hand− held tester, and read off various data output from the vehicle’s ECM. OBD II regulations require that the vehicle’s on− board computer lights up the Malfunction Indicator Lamp (MIL) on the instrument panel when the computer detects a malfunction in the computer itself or in drive system components which affect vehicle emissions. In addition to the MIL lighting up when a malfunction is detected, the applicable DTCs prescribed by SAE J2012 are recorded in the ECM memory (See page DI−13). If the malfunction does not occurs in 3 trips, the MIL goes off but the DTCs remain recorded in the ECM memory. S Q08225 TOYOTA Hand−held Tester S S DLC3 Q08634 To check the DTCs, connect an OBD II scan tool or TOYOTA hand−held tester to the DLC3 on the vehicle. The OBD II scan tool or TOYOTA hand−held tester also enables you to erase the DTCs and check freeze frame data and various forms of engine data (For operating instructions, see the OBDII scan tool’s instruction book). DTCs include SAE controlled codes and Manufacturer controlled codes. SAE controlled codes must be set as prescribed by the SAE, while Manufacturer controlled codes can be set freely by the manufacturer within the prescribed limits (See page DI−143). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−132 DIAGNOSTICS − AUTOMATIC TRANSMISSION The diagnosis system operates in normal mode during normal vehicle use, and also has a check mode for technicians to simulate malfunction symptoms and perform troubleshooting. Most DTCs use 2 trip detection logic(*) to prevent erroneous detection. By switching the ECM to check mode when troubleshooting, the technician can cause the MIL to light up for a malfunction that is only detected once or momentarily (TOYOTA hand−held tester) (See step 3). S *2 trip detection logic: When a logic malfunction is first detected, the malfunction is temporarily stored in the ECM memory. If the same malfunction is detected again during the 2nd test drive, this 2nd detection causes the MIL to light up. S 2. (a) Q08225 TOYOTA Hand−held Tester DLC3 Normal Mode: INSPECT DIAGNOSIS Check the MIL. (1) The MIL lights up when the ignition switch is turned ON and the engine is not running. HINT: If the MIL does not light up, troubleshoot the combination meter (See page BE−2). (2) When the engine is started, the MIL should go off. If the lamp remains on, the diagnosis system has detected a malfunction or abnormality in the system. (b) Check the DTC. NOTICE: TOYOTA hand−held tester only: When the diagnostic system is switched from the normal mode to the check mode, it erases all DTCs and freeze frame data recorded in the normal mode. So before switching modes, always check the DTCs and freeze frame data, and note them down. (1) Prepare the OBD II scan tool (complying with SAE J1978) or TOYOTA hand−held tester. (2) Connect the OBD II scan tool or TOYOTA hand− held tester to the DLC3 in the fuse box at the lower left of the instrument panel. (3) Turn the ignition switch ON and turn the OBD II scan tool or TOYOTA hand−held tester switch ON. Q08634 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−133 DIAGNOSTICS − (4) (5) TOYOTA Hand−held Tester DLC3 AUTOMATIC TRANSMISSION Use the OBD II scan tool or TOYOTA hand−held tester to check the DTCs and freeze frame data. Note them down (For operating instructions, see the OBD II scan tool’s instruction book). See page DI−143 to confirm the details of the DTCs. NOTICE: When simulating symptoms with an OBD II scan tool (excluding TOYOTA hand−held tester) to check the DTCs, use the normal mode. For codes on the DTC chart subject to ”2 trip detection logic”, turn the ignition switch off after the symptoms have been simulated for the 1st time. Them repeat the simulation process again. When the program has been simulated twice, the MIL lights up and the DTCs are recorded in the ECM. 3. Check Mode: INSPECT DIAGNOSIS HINT: TOYOTA hand−held tester only: Compared to the normal mode, the check mode has high sensing ability to detect malfunctions. Furthermore, the same diagnostic items which are detected in the normal mode can also be detected in check mode. (a) Check the DTC. (1) Check the initial conditions. S Battery positive voltage 11 V or more. S Throttle valve fully closed. S Transmission in P position. S Air conditioning switched off. (2) Turn the ignition switch OFF. (3) Prepare the TOYOTA hand−held tester. (4) Connect the TOYOTA hand−held tester to the DLC3 in the fuse box at the lower left of the instrument panel. (5) Turn the ignition switch ON and switch the TOYOTA hand−held tester ON. Q08634 (6) Flashing (7) (8) ON OFF 0.13 sec. FI3605 Switch the TOYOTA hand−held tester from the normal mode to the check mode (Check that the MIL flashes). Start the engine (The MIL goes). Simulate the conditions of the malfunction described by the customer. NOTICE: Leave the ignition switch ON until you have checked the DTCs etc. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−134 DIAGNOSTICS (9) − AUTOMATIC TRANSMISSION After simulating the malfunction conditions, use the TOYOTA hand−held tester diagnosis selector to check the DTCs and freeze frame data, etc. HINT: Take care not to turn the ignition switch OFF. Turning the ignition switch off switches the diagnosis system from check mode to normal mode, so all DTCs, etc. are erased. (10) After checking the DTC, inspect the applicable circuit. (b) Clear the DTC. The following actions will erase the DTCs and freeze frame data. Operating the OBD II scan tool (complying with SAE J1978) or TOYOTA hand−held tester to erase the codes (See the OBD II scan tool’s instruction book for operating instructions.). NOTICE: If the TOYOTA hand−held tester switches the ECM from the normal mode to the check mode or vice−versa, or if the ignition switch is turned from ON to ACC or OFF during the check mode, the DTCs and freezed frame data will be erased. (c) Check the DLC3. The vehicle’s ECM uses V.P.W. (Variable Pulse Width) for communication to comply with SAE J1850. The terminal arrangement of DLC3 complies with SAE J1962 and matches the V.P.W. format. DLC3 N09214 Terminal No. Connection/Voltage or Resistance Condition 2 Bus ę Line/Pulse generation During communication 4 Chassis Ground − Body/1 Ω or less Always 5 Signal Ground − Body/1 Ω or less Always 16 Battery Positive − Body/9 − 14 V or 1 Ω or less Always 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−135 DIAGNOSTICS − AUTOMATIC TRANSMISSION HINT: If your display shows ”UNABLE TO CONNECT TO VEHICLE” when you have connected the cable of the OBD II scan tool or TOYOTA hand−held tester to the DLC3, turned the ignition switch ON and operated the scan tool, there is a problem on the vehicle side or tool side. S If communication is normal when the tool is connected to another vehicle, inspect the DLC3 on the original vehicle. S If communication is still not possible when the tool is connected to another vehicle, the problem is probably in the tool itself, so consult the Service Department listed in the tool’s instruction manual. 4. CHECK FOR INTERMITTENT PROBLEMS TOYOTA hand−held tester only: By putting the vehicle’s ECM in the check mode, 1 trip detection logic is possible instead of 2 trip detection logic and sensitivity to detect open circuits is increased. This makes it easier to detect intermittent problems. (1) Clear the DTC (See step 3). (2) Set the check mode (See step 3). (3) Do a simulation test (See page IN−18). (4) Check the cnnector connection and terminal (See page IN−28). (5) Visual check and contact pressure (See page IN−28). (6) Handle the connector (See page IN−28). 5. ROAD TEST NOTICE: Perform the test at normal operating ATF temperature 50 − 80°C (122 − 176°F). (a) D position test in NORM and PWR pattern positions. Shift into the D position and hold the accelerator pedal constant at the full throttle valve opening position and check the following: HINT: When the 2nd start switch in on, there is no 1 → 2 up−shift and 2 → 1 down−shift. (1) 1 → 2, 2 → 3 and 3 → O/D up−shift takes place, and shift point should conform to those shown in the automatic shift schedule. Conduct a test under both Normal and Power patterns. HINT: There is no O/D up−shift or lock−up when the coolant temperature is below 55°C (131°F). Evaluation: S If there is no 1 → 2 up−shift: Shift solenoid valve No. 2 is stuck. 1−2 shift valve is stuck. S If there is no 2 → 3 up−shift: Shift solenoid valve No. 1 is stuck. 2−3 shift valve is stuck. S If there is no 3 → O/D up−shift: 3−4 shift valve is stuck. S If the shift point is defective: Throttle valve, 1−2 shift valve, 2−3 shift valve, 3−4 shift valve etc., are defective. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−136 DIAGNOSTICS − AUTOMATIC TRANSMISSION If the lock−up is defective: Lock−up solenoid is stuck. Lock−up control valve is stuck. Lock−up signal value is stuck. (2) In the same way, check the shock and slip at the 1 → 2, 2 → 3 and 3 → O/D up−shift. Evaluation: If the shock is excessive: Line pressure is too high. Accumulator is defective. Check ball is defective. (3) Run at the D position lock−up or O/D gear and check for abnormal noise and vibration. HINT: The check for the cause of abnormal noises and vibration must be made with extreme care as it could also be due to loss of balance in the propeller shaft, differential, torque converter clutch, etc. (4) While running in the D position, 2nd, 3rd and O/D gears, check to see that the possible kick−down vehicle speed limits for 2 → 1, 3 → 2 and O/D → 3 kick−downs conform to those indicated on the automatic shift schedule. (5) Check for abnormal shock and slip at kick−down. (6) Check for the lock−up mechanism. S Drive in D position, O/D gear, at a steady speed (lock−up ON) of about 95 km/h (59 mph). S Lightly depress the accelerator pedal and check that the engine RPM does not change abruptly. If there is a big jump in engine RPM, there is no lock−up. (b) 2 position test. Shift into the 2 position and, while driving with the accelerator pedal held constantly at the full throttle valve opening position, push in one of the pattern selectors and check the following points: HINT: When the 2nd start switch is on, there is no 1 → 2 up−shift and 2 → 1 down−shift. (1) Check to see that the 1 → 2 up−shift takes place and that the shift point conforms to the automatic shift schedule. HINT: There is no O/D up−shift and lock−up in the 2 position. (2) While running in the 2 position and 2nd gear, release the accelerator pedal and check the engine braking effect. Evaluation: If there is no engine braking effect: 2nd coast brake is defective. (3) Check for abnormal noise at acceleration and deceleration, and for shock at up−shift and down− shift. (c) L position test. (1) While running in the L position, check to see that there is no up−shift to 2nd gear. (2) While running in the L position, release the accelerator pedal and check the engine braking effect. Evaluation: If there is no engine braking effect: 1stand reverse brake is defective. (3) Check for abnormal noise during acceleration and deceleration. (d) R position test. Shift into the R position and fully depress the accelerator pedal and check for slipping. S 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−137 DIAGNOSTICS (e) − AUTOMATIC TRANSMISSION P position test. Stop the vehicle on a grade (more than 5°) and after shifting into the P position, release the parking brake. Then, check to see that the parking lock pawl holds the vehicle in place. 6. BASIC INSPECTION (a) Check the fluid level. HINT: S Drive the vehicle so that the engine and transmission are at normal operating temperature. Fluid temp.: 70 − 80°C (158 − 176°F) S Only use the COOL range on the dipstick as a rough reference when the ATF is replaced or the engine does not run. (1) OK if hot Add if hot AT3417 Park the vehicle on a level surface and set the parking brake. (2) With the engine idling and the brake pedal depressed, shift the shift lever into all positions from P to L position and return to P position. (3) Pull out the dipstick and wipe it clean. (4) Push it back fully into the pipe. (5) Pull it out and check that the fluid level is in the HOT range. If the level is at the low side, add new fluid. Fluid type: ATF DEXRON ®II NOTICE: Do not overfill. (b) Check the fluid condition. If the fluid smells burnt or is black, replace it. (c) Replace the ATF. (1) Remove the drain plug and drain the ATF. (2) Reinstall the drain plug securely. Q07273 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−138 DIAGNOSTICS − AUTOMATIC TRANSMISSION (3) With the engine OFF, add new fluid through the oil filler pipe. Fluid type: ATF DEXRON ®II Capacity: Dry fill: 11.0 liters (11.6 US qts, 9.7 Imp. qts) Drain and refill: 1.9 liters (2.0 US qts, 1.7 Imp. qts) (4) Start the engine and shift the shift lever into all positions from P to L position and then shift into P position. Q07308 (5) OK if hot (6) Add if hot AT3417 With the engine idling, check the fluid level. Add fluid up to the COOL level on the dipstick. Check the fluid level at the normal operating temperature 70 − 80°C (158 − 176°F) and add as necessary. NOTICE: Do not overfill. (d) Check the fluid leaks. Check for leaks in the transmission. If there are leaks, it is necessary to repair or replace O−rings, Seal packings, oil seals, plugs or other parts. (e) Inspect and adjust the throttle cable. (1) Check that the throttle valve is fully closed. (2) Check that the inner cable is not slack. (3) Measure the distance between the outer cable end and stopper on the cable. Standard distance: 0 − 1 mm (0 − 0.04 in.) If the distance is not standard, adjust the cable by the adjusting nuts. 0 − 1 mm AT4252 (f) Q07309 Inspect and adjust the shift lever position. When shifting the shift lever from the N position to other positions, check that the lever can be shifted smoothly and accurately to each position and that the position indicator correctly indicates the position. If the indicator is not aligned with the correct position, carry out the following adjustment procedures. (1) Loosen the nut on the control rod. (2) Push the control rod fully rearward. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−139 DIAGNOSTICS − AUTOMATIC TRANSMISSION (3) Return the control shaft lever 2 notches to N position. (4) Set the shift lever to N position. (5) While holding the shift lever lightly toward the R position side, adjust the control rod nut. (6) Tighten the control rod nut. Torque: 13 N·m (130 kgf·cm, 9 ft·lbf) (7) Start the engine and make sure that the vehicle moves forward when shifting the lever from the N to D position and reverses when shifting it to the R position. (c) (b) Control Shaft Lever Q07310 (g) Neutral Basic Line Bolt Groove Q07311 7. (a) Inspec and adjust park/neutral positoin switch. Check that the engine can be started with the shift lever only in the N or P position, but not in other positions. If not as stated above, carry out the following adjustment procedure. (1) Loosen the park/neutral position switch bolt and set the shift lever to the N position. (2) Align the groove and neutral basic line. (3) Hold in position and tighten the bolt. Torque: 13 N·m (130 kgf·cm, 9 ft·lbf) For continuity inspect of the park/neutral position switch, see page DI−169. (h) Check the idle speed. Idle speed: 650 ± 50 rpm (In N position and air conditioner OFF) MECHANICAL SYSTEM TESTS Measure the stall speed. The object of this test is to check the overall performance of the transmission and engine by measuring the stall speeds in the D and R positions. NOTICE: S Do the that at normal operating ATF temperature 50 − 80°C (122 − 176°F). S Do not continuously run this test longer than 5 seconds. S To ensure safety, conduct this test in a wide, clear, level area which provides good traction. S The stall test should always be carried out in pairs. One technician should observe the conditions of wheels or wheel stoppers outside the vehicle while the other is doing the test. (1) Chock the 4 wheels. (2) Connect an OBD II scan tool or TOYOTA hand−held tester to the DLC3. (3) Fully apply the parking brake. (4) Keep your left foot pressed firmly on the brake pedal. (5) Start the engine. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−140 DIAGNOSTICS − AUTOMATIC TRANSMISSION (6) Shift into the D position. Press all the way down on the accelerator pedal with your right foot. Quickly read the stall speed at this time. Stall speed: 1,950 ± 150 rpm (7) Do the same test in R position. Stall speed: 1,950 ± 150 rpm Evaluation: Problem Possible cause Stall speed low in D and R positions S Engine output may be insufficient S Stator one−way clutch is operating properly HINT: If more than 600 rpm below the specified value, the torque converter clutch could be faulty. Stall speed high in D position S Line pressure too low S Forward clutch slipping S No. 2 one−way clutch not operating properly S O/D one−way clutch not operating properly Stall speed high in R position S Line pressure too low S Direct clutch slipping S 1st and reverse brake slipping S O/D clutch slipping Stall speed high in D and R positions S Line pressure too low S Improper fluid level S O/D one−way clutch not operating properly (b) Measure the time lag. When the shift lever is shifted while the engine is idling, there will be a certain time lapse or lag before the shock can be felt. This is used for checking the condition of the O/D direct clutch, forward clutch, direct clutch and 1st and reverse brake. NOTICE: S Do the test at normal operating ATF temperature 50 − 80°C (122 − 176°F). S Be sure to allow 1 minute interval between tests. S Take 3 measurements and take the average value. (1) Fully apply the parking brake. (2) Start the engine and check idle speed. Idle speed: 650 ± 50 rpm (In N position and air conditioner OFF) (3) Shift the shift lever from N to D position. Using a stop watch, measure the time it takes from shifting the lever until the shock is felt. In the same manner, measure the time lag for N → R. Time lag: N → D Less than 1.2 seconds In the same way, measure the time lag for N → R. Time lag: N → R Less than 1.5 seconds If N → D time or N → R time lag is longer than specified: Evaluation: Problem Possible cause N → D time lag is longer S Line pressure too low S Forward clutch worn S O/D one−way clutch not operating properly N → R time lag is longer S Line pressure too low S Direct clutch worn S 1st and reverse brake worn S O/D one−way clutch not operating properly 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−141 DIAGNOSTICS − AUTOMATIC TRANSMISSION 8. HYDRAULIC TEST Measure the line pressure. NOTICE: S Do the test at normal operation ATF temperature 50 − 80°C (122 − 176°F). S The line pressure test should always be carried out in pairs. One technician should observe the conditions of wheels or wheel stoppers outside the vehicle while the other is doing the test. S Be careful to prevent SST’s hose from interfering with the exhaust pipe. (1) Warm up the ATF. (2) Remove the test plug on the transmission case right side and connect SST (See page AT−18 for the location to connect SST). SST 09992−00094 (09992−00150, 09992−00270) (3) Fully apply the parking brake and chock the 4 wheels. (4) Start the engine and check idling speed. (5) Keep your left foot pressed firmly on the brake pedal and shift into D position. (6) Measure the line pressure when the engine is idling. (7) Press the accelerator pedal all the way down. Quickly read the highest line pressure when engine speed reaches stall speed. NOTICE: Release the accelerator pedal and stop test if the rear wheels begin to rotate before the engine speed reaches the specified stall speed. (8) In the same manner, do the test in R position. Specified line pressure: Condition D position kPa (kgf/cm2, psi) R position kPa (kgf/cm2, psi) Idling 422 − 481 (4.3 − 4.9, 61 − 70) 510 − 608 (5.2 − 6.2, 74 − 88) Stall 1,285 − 1,530 (13.1 − 15.6, 128 − 153) 1,579 − 1,932 (16.1 − 19.7, 158 − 193) If the measured pressures are not up to specified values, recheck the throttle cable adjustment and retest. Evaluation: Problem Possible cause If the measured value at all positions are higher S Throttle cable out of adjustment S Throttle valve defective S Regulator valve defective If the measured value at all positions are lower S Throttle cable out of adjustment S Throttle valve defective S Regulator valve defective S Oil pump defective S O/D direct clutch defective If pressure is low in the D position only S D position circuit fluid leakage S Forward clutch defective If pressure is low in the R position only S R position circuit fluid leakage S Direct clutch defective S 1st and reverse brake defective 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−142 DIAGNOSTICS Q07312 − AUTOMATIC TRANSMISSION 9. MANUAL SHIFTING TEST The purpose of this manual shifting test is to determine whether a problem is caused by either mechanical or electrical factors. Disconnecting the solenoid wire disables electrically−controlled automatic gear shifting. In this case, operating the shift lever is the only way to shift the transmission gear. If the gear is not changed by shift lever operation, it is assumed that there is a mechanical problem. (a) Turn the ignition switch OFF. (b) Disconnect the solenoid wire connector. (c) Warm up the engine. (d) Drive the vehicle. (e) Check the transmission operation when the shift lever is moved into L, 2 and D positions. Standard: Shift Lever Operation L to 2 Shift up 2 to D Shift up D to 2 Shift down 2 to L Shift down (f) Turn the ignition switch OFF. (g) Connect the solenoid wire connector. (h) Clear DTCs. HINT: When the solenoid wire is disconnected, the transmission gear will be set as listed below: Shift Lever Gear P Parking R Reverse N Neutral D O/D (4th) 2 3rd L 1st 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−143 DIAGNOSTICS − AUTOMATIC TRANSMISSION DI5KB−03 DIAGNOSTIC TROUBLE CODE CHART If a DTC is displayed during the DTC check, check the circuit listed for that code in the table below and proceed to the page given. DTC No. (See page) Detection Item Trouble Area MIL* Memory P0500 (DI−153) Vehicle Speed Sensor Malfunction (No. 1 Vehicle Speed Sensor) S Open or short in No. 1 vehicle speed sensor circuit S No. 1 vehicle speed sensor S ECM F f P0710 (DI−154) Transmission Fluid Temperature Sensor Malfunction (ATF Temperature Sensor) S Open or short in ATF temperature sensor circuit S ATF temperature sensor S ECM F f P0750 (DI−156) Shift Solenoid A Malfunction (Shift Solenoid Valve No. 1) S Shift solenoid valve No. 1 is stuck open or closed S Valve body is blocked up or stuck F f P0753 (DI−157) Shift Solenoid A Electrical Malfunction (Shift Solenoid Valve No. 1) S Open or short in shift solenoid valve No. 1 circuit S Shift solenoid valve No. 1 S ECM F f P0755 (DI−156) Shift Solenoid B Malfunction (Shift Solenoid Valve No. 2) S Shift solenoid valve No. 2 is stuck open or closed S Valve body is blocked up or stuck F f P0758 (DI−157) Shift Solenoid B Electrical Malfunction (Shift Solenoid Valve No. 2) S Open or short in shift solenoid valve No. 2 circuit S Shift solenoid valve No. 2 S ECM F f P0770 (DI−161) Shift Solenoid E Malfunction (Shift Solenoid Valve SL) S Shift solenoid valve SL is stuck open or closed S Valve body is blocked up or stuck S Lock−up clutch F f P0773 (DI−163) Shift Solenoid E Electrical Malfunction (Shift Solenoid Valve SL) S Open or short in shift solenoid valve SL circuit S Shift solenoid valve SL S ECM F f P1700 (DI−166) Speed Sensor No. 2 Circuit Malfunction (No. 2 Vehicle Speed Sensor) S Open or short in No. 2 vehicle speed sensor circuit S No. 2 vehicle speed sensor S ECM F f P1780 (DI−169) Park/Neutral Position Switch Malfunction S Short in park/neutral position switch circuit S Park/neutral position switch S ECM F f *: F ...MIL light up 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−144 DIAGNOSTICS − AUTOMATIC TRANSMISSION DI5KD−02 PARTS LOCATION O/D OFF Indicator Light MIL O/D Main Switch Pattern Select Switch ECM ATF Temperature Sensor DLC3 DLC1 Transfer Neutral Position Switch Throttle Position Sensor L4 Position Sensor No. 1 Vehicle Speed Sensor No. 2 Vehicle Speed Sensor Engine Coolant Temperature Sensor Shift Solenoid Valve No. 2 Park/Neutral Position Switch Shift Solenoid Valve No. 1 Shift Solenoid Valve SL Stop Light Switch Q08236 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−145 DIAGNOSTICS − AUTOMATIC TRANSMISSION DI5KE−03 TERMINALS OF ECM ECM Terminals 13 12 11 10 E4 9 8 E5 7 6 5 4 3 2 1 26 25 24 23 22 21 20 19 18 17 16 15 14 8 7 6 5 4 E6 3 2 16 15 14 13 12 11 10 1 9 6 5 4 3 12 11 10 9 E7 2 8 3 2 1 1 11 10 9 8 7 22 21 20 19 18 17 16 15 14 13 12 7 6 5 4 D00115 Vd−76−2 Symbols (Terminal No.) Wiring Color Condition STD Voltage (V) Disconnect cruise control connector and IG ON SPD (E7−8) − E1 (E4−24) L−W − BR−B Disconnect cruise control connector and IG ON Turn one rear wheel slowly IG OFF S1 (E4−10) − E1 (E4−24) R − BR−B Disconnect ECM connector R−Y − BR−B R−L − BR−B 9 − 14 3rd or O/D gear Below 1.5 Disconnect ECM connector IG ON (E6−2) − V − V−G OD1 (E7−18) − E1 (E4−24) G−O − BR−B OD2 (E7−19) − E1 (E4−24) P−L − BR−B OIL (E5−12) − E2 (E5−9) R−W − BR−B L (E7−17) − E1 (E4−24) G−W − BR−B 2 (E7−16) − E1 (E4−24) O − BR−B R (E7−15) − E1 (E4−24) R−B − BR−B NSW (E7−22) − E1 (E4−24) B−W − BR−B STP (E7−14) − E1 (E4−24) G−W − BR−B THW (E5−4) − E2 (E5−9) R−W − BR−B IDL (E5−11) − E2 (E5−9) G−W − BR−B 11 − 15 Ω Below 1.5 2nd or 3rd gear 9 − 14 1st or O/D gear Below 1.5 Disconnect ECM connector IG ON 11 − 15 Ω Below 1.5 IG OFF SP− (E6−8) 11 − 15 Ω 9 − 14 Vehicle driving under lock−up position SP2+ Pulse signal is output Below 1.5 ↔ 4 − 6 1st or 2nd gear IG OFF SL (E4−8) − E1 (E4− 24) Below 1.5 IG ON IG OFF S2 (E4−9) − E1 (E4−24) Stationary 9 − 14 Disconnect ECM connector 560 − 680 Ω Pulse signal is output Below 1.5 ↔ 4 − 6 Engine is running IG ON 9 − 14 O/D main switch ON (O/D OFF) Below 3 O/D main switch OFF (O/D ON) 9 − 14 ATF temperature: 110°C (230°F) Below 1.5 IG ON Shift lever L position IG ON Shift lever other than L position IG ON Shift lever 2 position IG ON Shift lever other than 2 position IG ON Shift lever R position IG ON Shift lever other than R position IG ON Shift lever P or N position IG ON Shift lever other than P and N position IG ON Brake pedal is depressed IG ON Brake pedal is released Below 1.5 IG ON Engine coolant temperature 80°C (176°F) Below 1.5 IG ON Accel. pedal is released Below 1.5 IG ON Accel. pedal is depressed 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 7.5 − 14 Below 1.5 7.5 − 14 Below 1.5 7.5 − 14 Below 1.5 Below 3 9 − 14 7.5 − 14 9 − 14 Brought to you by BirfMark DI−146 DIAGNOSTICS VTA (E5−10) − E2 (E5−9) G−B − BR−B PWR (E7−20)− E1 (E4−24) P−B − BR−B TFN (E7−21)− E1 (E4−24) Y−L − BR−B L4SW (E7−9)− E1 (E4−24) B−L − BR−B HOLD (E4−3) − E1 (E4−24) O − BR−B HI (E4−18) − E1 (E4−24) R−W − BR−B − AUTOMATIC TRANSMISSION IG ON Accel. pedal is released Below 0.3 − 0.8 IG ON Accel. pedal is depressed 3.2 − 4.9 IG ON Pattern select switch ”NORM” Below 1.5 IG ON Pattern select switch ”PWR” 7.5 − 14 IG ON Transfer N position Below 3 IG ON Transfer other than N position IG ON Transfer L4 position IG ON Transfer other than L4 position 9 − 14 7.5 − 14 Below 1.5 IG ON 2nd start switch ON 9 − 14 IG ON 2nd start switch OFF Below 1.5 IG ON 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 7.5 − 14 Brought to you by BirfMark DI−147 DIAGNOSTICS − AUTOMATIC TRANSMISSION DI5KH−03 PROBLEM SYMPTOMS TABLE If a normal code is displayed during the diagnostic trouble code check but the trouble still occurs, check the circuits for each symptom in the order given in the charts on the following pages and proceed to the page given for troubleshooting. The Matrix Chart is divided into 3 chapters. Chapter 1: Electronic Circuit Matrix Chart Chapter 2: On−Vehicle repair Matrix Chart Chapter 3: Off−Vehicle repair Matrix Chart When troubleshooting, check Chapter 1 first. If instructions are given in Chapter 1 to proceed to chapter 2 or 3, proceed as instructed. (1) If the instruction ”Proceed to next circuit inspection shown on matrix chart” is given in the flow chart for each circuit, proceed to the circuit with the next highest number in the table to continue the check. (2) If the trouble still occurs even though there are no abnormalities in any of the other circuits, then check and replace the ECM. Chapter 1: Electronic Circuit Matrix Chart Symptom Suspect Area See page Vehicle does not move in any forward position and reverse position 6. On−vehicle repair matrix chart 7. Off−vehicle repair matrix chart − − Vehicle does not move in a particular position or positions 1. On−vehicle repair matrix chart 2. Off−vehicle repair matrix chart − − No up−shift (1st → 2nd) 1. 2. 3. 4. 5. 6. 7. 8. Shift solenoid valve No. 1 and No. 2 circuit Throttle position sensor circuit No. 1 vehicle speed sensor circuit No. 2 vehicle speed sensor circuit On−vehicle repair matrix chart Park/neutral position switch circuit Off−vehicle repair matrix chart ECM DI−157 DI−35 DI−87 DI−166 − DI−169 − DI−145 No up−shift (2nd → 3rd) 1. 2. 3. 4. 5. 6. 7. 8. Shift solenoid valve No. 1 and No. 2 circuit Throttle position sensor circuit No. 1 vehicle speed sensor circuit No. 2 vehicle speed sensor circuit On−vehicle repair matrix chart Park/neutral position switch circuit Off−vehicle repair matrix chart ECM DI−157 DI−35 DI−87 DI−166 − DI−169 − DI−145 No up−shift (3rd → O/D) 1. O/D main switck& O/D OFF indicator light circuit 2. Shift solenoid valve No. 1 and No. 2 circuit 3. No. 1 vehicle speed sensor circuit 4. No. 2 vehicle speed sensor circuit 5. Throttle position sensor circuit 6. Park/neutral position switch circuit 7. O/D cancel signal circuit 8. Engine coolant temp. sensor circuit 9. On−vehicle repair matrix chart 10.Off−vehicle repair matrix chart 11.ECM 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 DI−174 DI−157 DI−87 DI−166 DI−35 DI−169 DI−172 DI−30 − − DI−145 Brought to you by BirfMark DI−148 DIAGNOSTICS − AUTOMATIC TRANSMISSION No down−shift (O/D → 3rd) 1. 2. 3. 4. 5. 6. Shift solenoid valve No. 1 and No. 2 circuit Throttle position sensor circuit No. 1 vehicle speed sensor circuit No. 2 vehicle speed sensor circuit On−vehicle repair matrix chart ECM DI−157 DI−35 DI−87 DI−166 − DI−145 No down−shift (3rd → 2nd) 1. 2. 3. 4. 5. 6. Shift solenoid valve No. 1 and No. 2 circuit Throttle position sensor circuit No. 1 vehicle speed sensor circuit No. 2 vehicle speed sensor circuit On−vehicle repair matrix chart ECM DI−157 DI−35 DI−87 DI−166 − DI−145 No down−shift (2nd → 1st) 1. 2. 3. 4. 5. 6. 7. Shift solenoid valve No. 1 and No. 2 circuit Throttle position sensor circuit No. 1 vehicle speed sensor circuit No. 2 vehicle speed sensor circuit On−vehicle repair matrix chart Off−vehicle repair matrix chart ECM DI−157 DI−35 DI−87 DI−166 − − DI−145 Lock−up does not engage 1. Shift solenoid valve SL circuit 2. Throttle position sensor circuit 3. No. 1 vehicle speed sensor circuit 4. No. 2 vehicle speed sensor circuit 5. Stop light switch circuit 6. Park/neutral position switch circuit 7. Engine coolant temp. sensor circuit 8. On−vehicle repair matrix chart 9. Off−vehicle repair matrix chart 10.ECM DI−163 DI−35 DI−87 DI−166 DI−185 DI−169 DI−30 − − DI−145 Lock−up does not disengage 1. 2. 3. 4. 5. 6. 7. 8. Shift solenoid valve SL circuit Throttle position sensor circuit No. 1 vehicle speed sensor circuit No. 2 vehicle speed sensor circuit Stop light switch circuit On−vehicle repair matrix chart Off−vehicle repair matrix chart ECM DI−163 DI−35 DI−87 DI−166 DI−185 − − DI−145 Shift point too high or too low 1. 2. 3. 4. 5. Throttle position sensor circuit Pattern select switch circuit No. 1 vehicle speed sensor circuit No. 2 vehicle speed sensor circuit ECM DI−35 DI−179 DI−87 DI−166 DI−145 Up−shifts to 2nd while in L position Up−shifts to 3rd while in L position 1. Park/neutral position switch circuit 2. ECM DI−169 DI−145 Up−shifts to O/D from 3rd while O/D main switch is OFF 1. O/D main switck& O/D OFF indicator light circuit 2. ECM DI−174 DI−145 Up−shift to O/D from 3rd while engine is cold 1. 2. 3. 4. DI−30 − − DI−145 Engine coolant temp. sensor circuit On−vehicle repair matrix chart Off−vehicle repair matrix chart ECM 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−149 DIAGNOSTICS − AUTOMATIC TRANSMISSION Harsh engagement (N → D) 1. 2. 3. 4. 5. 6. 7. Shift solenoid valve SL circuit ATF temp. sensor circuit Throttle position sensor circuit Park/neutral position switch circuit On−vehicle repair matrix chart Off−vehicle repair matrix chart ECM DI−163 DI−154 DI−35 DI−169 − − DI−145 Harsh engagement (Lock−up) 1. 2. 3. 4. 5. 6. 7. Shift solenoid valve SL circuit Throttle position sensor circuit No. 1 vehicle speed sensor circuit No. 2 vehicle speed sensor circuit On−vehicle repair matrix chart Off−vehicle repair matrix chart ECM DI−163 DI−35 DI−87 DI−166 − − DI−145 Harsh engagement (Any driving position) 1. 2. 3. 4. 5. 6. 7. 8. Shift solenoid valve SL circuit ATF temp. sensor circuit Throttle position sensor circuit No. 1 vehicle speed sensor circuit No. 2 vehicle speed sensor circuit On−vehicle repair matrix chart Off−vehicle repair matrix chart ECM DI−163 DI−154 DI−35 DI−87 DI−166 − − DI−145 Slip or shudder (Forward and reverse) 1. On−vehicle repair matrix chart 2. Off−vehicle repair matrix chart − − Slip or shudder (A particular position) 1. On−vehicle repair matrix chart 2. Off−vehicle repair matrix chart − − No engine braking 1. On−vehicle repair matrix chart 2. Off−vehicle repair matrix chart − − Poor acceleration 1. 2. 3. 4. 5. 6. 7. Throttle position sensor circuit No. 1 vehicle speed sensor circuit No. 2 vehicle speed sensor circuit Shift solenoid valve No. 1 and No. 2 circuit Shift solenoid valve SL circuit On−vehicle repair matrix chart Off−vehicle repair matrix chart DI−35 DI−87 DI−166 DI−157 DI−163 − − No kick−down 1. 2. 3. 4. 5. Throttle position sensor circuit Shift solenoid valve No. 1 and No. 2 circuit No. 1 vehicle speed sensor circuit On−vehicle repair matrix chart ECM DI−35 DI−157 DI−87 − DI−145 No pattern select 1. Pattern select switch circuit 2. ECM DI−179 DI−145 No 2nd start 1. Pattern select switch circuit 2. Shift solenoid valve No. 1 and No. 2 circuit 3. ECM DI−179 DI−157 DI−145 Large shift shock or engine stalls when starting off or stopping 1. 2. 3. 4. DI−163 DI−185 − DI−145 Shift solenoid valve SL circuit Stop light switch circuit Off−vehicle repair matrix chart ECM 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−150 DIAGNOSTICS − AUTOMATIC TRANSMISSION Chapter 2: On−Vehicle Repair (L: A340F, A343F Automatic Transmission Repair Manual Pub. No. RM479U) Symptom Suspect Area Throttle cable Transmission control rod Manual valve Primary regulator valve Parking lock pawl Off−vehicle repair matrix chart See page Vehicle does not move in any forward position and reverse position 1. 2. 3. 4. 5. 6. Vehicle does not move in R position 1. Off−vehicle repair matrix chart − Vehicle does not move in a particular position or positions (Except R position) 1. Off−vehicle repair matrix chart − No up−shift (1st → 2nd) 1. 1−2 shift valve 2. Off−vehicle repair matrix chart L − No up−shift (2nd → 3rd) 1. 2−3 shift valve 2. Off−vehicle repair matrix chart L − No up−shift (3rd → O/D) 1. 3−4 shift valve 2. Off−vehicle repair matrix chart L − No down−shift (O/D → 3rd) 1. 3−4 shift valve L No down−shift (3rd → 2nd) 1. 2−3 shift valve L No down−shift (2nd → 1st) 1. 1−2 shift valve 2. Off−vehicle repair matrix chart L − Lock−up does not engage or lock−up does not disengage 1. Lock−up relay valve 2. Off−vehicle repair matrix chart L − Harsh engagement (N → D) 1. Accumulator control valve 2. Off−vehicle repair matrix chart L − Harsh engagement (Lock−up) 1. Lock−up control valve 2. Off−vehicle repair matrix chart L − Harsh engagement (N → R) 1. Accumulator control valve 2. C2 accumulator 3. Off−vehicle repair matrix chart L L − Harsh engagement (N → L) 1. Low coast modulator valve L Harsh engagement (1st → 2nd (D position)) 1. Accumulator control valve 2. B2 accumulator L L Harsh engagement (1st → 2nd (2 position)) 1. Accumulator control valve 2. B2 accumulator L L Harsh engagement (2nd → 3rd → O/D) 1. Cut−back valve L Harsh engagement (1st → 2nd → 3rd → O/D) 1. Throttle valve 2. Accumulator control valve L L Harsh engagement (2nd → 3rd) 3. Accumulator control valve 1. C2 accumulator 2. Off−vehicle repair matrix chart L L − Harsh engagement (3rd → O/D) 1. Accumulator control valve 2. B0 accumulator 3. Off−vehicle repair matrix chart L L − Harsh engagement (O/D → 3rd) 1. Accumulator control valve 2. C0 accumulator 3. Off−vehicle repair matrix chart L L − 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 DI−131 DI−131 L L L − Brought to you by BirfMark DI−151 DIAGNOSTICS − AUTOMATIC TRANSMISSION Slip or shudder (Forward and reverse) 1. 2. 3. 4. 5. Throttle cable Transmission control rod Oil strainer Pressure relief valve Off−vehicle repair matrix chart DI−131 DI−131 L L − Slip or shudder (Particular position) 1. Throttle cable 2. Transmission control rod 3. Off−vehicle repair matrix chart DI−131 DI−131 − No engine braking (1st (L position)) 1. Low coast modulator 2. Off−vehicle repair matrix chart L − No engine braking (2nd (2 position)) 1. 2nd coast modulator 2. Off−vehicle repair matrix chart L − No kick−down 1. 1−2 shift valve 2. 2−3 shift valve L L Chapter 3: Off−Vehicle Repair (L: A340F, A343F Automatic Transmission Repair Manual Pub. No. RM479U) Symptom Suspect Area See page Vehicle does not move in any forward position and reverse position 1. O/D one−way clutch (F0) 2. O/D planetary gear unit 3. Torque converter clutch Vehicle does not move in R position 1. 2. 3. 4. Vehicle does not move in D, 2 and L positions 1. Forward clutch (C1) L Vehicle does not move in D and 2 positions 1. No. 2 one−way clutch (F2) L Vehicle does not move in 2 position 1. 1st and reverse brake (B3) L Vehicle does not move in L position 1. 2nd brake (B2) 2. 2nd coast brake (B1) 3. Direct clutch (C2) L L L No up−shift (1st → 2nd) 1. 2nd brake (B2) 2. No. 1 one−way clutch (F1) L L No up−shift (2nd → 3rd) 1. Direct clutch (C2) L No up−shift (3rd → O/D) 1. O/D brake (B0) L No down−shift (2nd → 1st) 1. 2nd brake (B2) L Lock−up does not engage or lock−up does not disengage 1. Torque converter clutch Harsh engagement (N → D) 1. Forward clutch (C1) 2. O/D one−way clutch (F0) 3. No. 2 one−way clutch (F2) L L L Harsh engagement (N → R) 1. Direct clutch (C2) 2. 1st and reverse brake (B3) 3. O/D one−way clutch (F0) L L L Harsh engagement (2nd → 3rd) 1. Direct clutch (C2) L Harsh engagement (3rd → O/D) 1. O/D brake (B0) 2. O/D planetary gear unit L L Harsh engagement (O/D → 3rd) 1. O/D one−way clutch (F0) L Harsh engagement (Lock−up) 1. Torque converter clutch AT−26 Slip or shudder (Forward and reverse (After warm−up)) 1. Torque converter clutch 2. O/D one−way clutch (F0) 3. O/D direct clutch (C0) AT−26 L L Slip or shudder (Forward and reverse (Just after engine starts)) 1. Torque converter clutch AT−26 2nd coast brake (B1) Front and rear planetary gear unit Direct clutch (C2) 1st and reverse brake (B3) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 L L AT−26 L L L L AT−26 Brought to you by BirfMark DI−152 DIAGNOSTICS − AUTOMATIC TRANSMISSION Slip or shudder (R position) 1. Direct clutch (C2) 2. 1st and reverse brake (B3) 3. O/D one−way clutch (F0) L L L Slip or shudder (1st) 1. Forward clutch (C1) 2. No. 2 one−way clutch (F2) 3. O/D one−way clutch (F0) L L L Slip or shudder (2nd) 1. 2nd brake (B2) 2. 2nd coast brake (B1) 3. No. 1 one−way clutch (F1) L L L Slip or shudder (3rd) 1. Direct clutch (C2) L Slip or shudder (O/D) 1. O/D brake (B0) L No engine braking (1st − 3rd) 1. O/D direct clutch (C0) L No engine braking (1st) 1. 1st and reverse brake (B3) L No engine braking (2nd) 1. 2nd coast brake (B1) L Poor acceleration (All positions) 1. Torque converter clutch AT−26 Poor acceleration (O/D) 1. O/D brake (B0) 2. O/D planetary gear unit L L Poor acceleration (Other than O/D) 1. O/D brake (B0) L Poor acceleration (Other than 2nd) 1. 2nd coast brake (B1) 2. No. 1 one−way clutch (F1) L L Poor acceleration (1st and 2nd) 1. O/D one−way clutch (F0) L Poor acceleration (L and R positions) 1. 1st and reverse brake (B3) L Poor acceleration (R position) 1. Forward clutch (C1) Engine stalls when starting off or stopping 1. Torque converter clutch 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 L AT−26 Brought to you by BirfMark DI−153 DIAGNOSTICS − AUTOMATIC TRANSMISSION DI5KI−01 CIRCUIT INSPECTION DTC P0500 Vehicle Speed Sensor Malfunction (No. 1 Vehicle Speed Sensor) See page DI−87. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−154 DIAGNOSTICS − AUTOMATIC TRANSMISSION DI5KK−02 DTC P0710 Transmission Fluid Temperature Sensor Circuit Malfunction (ATF Temperature Sensor) CIRCUIT DESCRIPTION The ATF temperature sensor converts fluid temperature into resistance value which is input into the ECM. DTC No. DTC Detecting Condition Trouble Area P0710 Either (a) or (b) is detected for 0.5 sec. or more (a) Temp. sensor resistance is less than 79 Ω (b) After the engine has been operating for 15 min. or more, the resistance at the temp. sensor is more than 156 kΩ S Open or short in ATF temp. sensor circuit S ATF temp. sensor S ECM WIRING DIAGRAM ECM 4−6V ATF Temperature Sensor 2 R−W 12 E5 OIL 1 BR−B 9 E2 E5 Q04346 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−155 DIAGNOSTICS − AUTOMATIC TRANSMISSION INSPECTION PROCEDURE 1 Check ATF temperature Sensor. 20°C and 110°C Q07002 PREPARATION: Remove the ATF temperature sensor. CHECK: Measure the resistance between terminals of the ATF temperature sensor at 20°C (68°F) and 110°C (230°F). OK: Resistance : 20°C (68°F): Approx. 12.2 kΩ 110°C (230°F): Approx. 770 Ω NG Replace ATF temperature sensor. OK 2 Check harness and connector between ATF temperature sensor and ECM (See page IN−28). NG Repair or replace harness or connector. OK Check and replace ECM. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−156 DIAGNOSTICS − AUTOMATIC TRANSMISSION DI5KM−02 DTC P0750, P0755 Shift Solenoid A/B Malfunction (Shift Solenoid Valve No. 1/No. 2) SYSTEM DESCRIPTION The ECM uses signals from the vehicle speed sensor to detect the actual gear position (1st, 2nd, 3rd or O/D gear). Then the ECM compares the actual gear with the shift schedule in the ECM memory to detect mechanical trouble of the shift solenoid valves and valve body. DTC No. P0750 P0755 DTC Detecting Condition Trouble Area During normal driving, the gear required by the ECM does not match the actual gear (2 trip detection logic) S Shift solenoid valve No. 1/No. 2 is stuck open or closed S Valve body is blocked up or stuck HINT: Check the shift solenoid valve No. 1 when DTC P0750 is output and check shift solenoid valve No. 2 when DTC P0755 is output. INSPECTION PROCEDURE 1 (+) Check shift solenoid valve No. 1 or No. 2 operation. PREPARATION: (a) Remove the oil pan. (b) Remove the shift solenoid valve No. 1 or No. 2. CHECK: (a) Applying 490 kPa (5 kgf/cm2, 71 psi) of compressed air, check that the shift solenoid valve does not leak air. (b) When battery positive voltage is supplied to the shift solenoid valves, check they opens. (−) Air (+) (−) Q08220 Q08221 D00081 NG Replace shift solenoid valve No. 1 or No. 2. OK 2 Check valve body (See page DI−147). NG Repair or replace valve body. OK Repair transmission (See page AT−18). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−157 DIAGNOSTICS − AUTOMATIC TRANSMISSION DI5KO−02 DTC P0753, P0758 Shift Solenoid A/B Electrical Malfunction (Shift Solenoid Valve No. 1/No. 2) CIRCUIT DESCRIPTION Shifting from 1st to O/D is done in combination with ON and OFF of the shift solenoid valves No. 1 and No. 2 controlled by ECM. If an open or short circuit occurs in either of the shift solenoid valves, the ECM controls the remaining normal shift solenoid valve to allow the vehicle to be operated smoothly (Fail safe function). Fail Safe Function: If either of the shift solenoid valve circuits develops an open or short, the ECM turns the other shift solenoid ON and OFF to shift to the gear positions shown in the table below. The ECM also turns the shift solenoid valve SL OFF at the same time. If both solenoids are malfunction, hydraulic control cannot be done electronically and must be done manually. Manual shifting as shown in the following table must be done (In the case of a short circuit, the ECM stops sending current to the short circuited solenoid). SHIFT SOLENOID NO. 1 MALFUNCTIONING NORMAL Position D 2 L Solenoid valve No. 1 No. 2 ON OFF Gear BOTH SOLENOIDS MALFUNCTIONING Gear when shift selector is manually operated 1st O/D 3rd Solenoid valve No. 1 No. 2 ON X X ON 3rd OFF X O/D O/D X ON 3rd OFF X O/D O/D O/D X OFF O/D OFF X O/D O/D 1st X ON 3rd ON X 1st 3rd ON 2nd X ON 3rd OFF X 3rd 3rd ON 3rd X ON 3rd OFF X 3rd 3rd 1st X OFF 1st ON X 1st 1st 2nd X ON 2nd ON X 1st 1st Gear 1st ON ON 2nd OFF ON 3rd OFF OFF ON OFF ON OFF ON OFF ON ON Solenoid valve No. 1 No. 2 ON X SHIFT SOLENOID NO. 2 MALFUNCTIONING Gear X: Malfunctions HINT: Check the shift solenoid valve No. 1 when DTC P0753 is output and check the shift solenoid valve No. 2 when DTC P0758 is output. DTC No. DTC Detecting Condition P0753 P0758 The ECM checks for an open or short circuit in the shift solenoid valves No. 1 and No. 2 circuit when it changes The ECM records DTC P0753 or P0758 if condition (a) or (b) is detected once, but it does not light up MIL After ECM detects condition (a) or (b) continuously 8 times or more in one−trip, it causes the MIL light up until condition (a) or (b) disappears After that, if the ECM detects condition (a) or (b) once, it starts lighting up MIL again (a) Solenoid resistance is 8 Ω or less (short circuit) when the solenoid is energized (b) Solenoid resistance is 100 kΩ or more (open circuit) when the solenoid is not energized Trouble Area S Open or short in shift solenoid valve No. 1/No. 2 circuit S Shift solenoid valve No. 1/No. 2 S ECM 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−158 DIAGNOSTICS − AUTOMATIC TRANSMISSION WIRING DIAGRAM ECM Transmission Shift Solenoid Valve No. 1 W 1 Shift Solenoid Valve No. 2 B 2 B+ 1 R R EC2 10 E4 S1 B+ 2 R−Y EC2 R−Y 9 E4 S2 R−Y From Cruise Control ECU Q07463 INSPECTION PROCEDURE 1 Measure resistance between terminal S1 or S2 of ECM and body ground. S1 PREPARATION: Disconnect the connector from the ECM. CHECK: Measure the resistance between terminal S1 or S2 of the ECM and body ground. OK: Resistance: 11 − 15 Ω S2 Q07641 OK Check and replace ECM. NG 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−159 DIAGNOSTICS 2 − AUTOMATIC TRANSMISSION Check harness and connector between ECM and automatic transmission solenoid connector. S1 S2 PREPARATION: Disconnect the solenoid connector from the automatic transmission. CHECK: Check the harness and connector between terminals S1 or S2 of the ECM and S1 or S2 terminals of the solenoid connector. OK: There is no open and no short circuit. S2 S1 Q07643 Q07312 D00082 NG Repair or replace harness or connector. OK 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−160 DIAGNOSTICS 3 − AUTOMATIC TRANSMISSION Check shift solenoid valve No. 1 or No. 2. Q08222 Q08224 D00083 PREPARATION: (a) Jack up the vehicle. (b) Remove the oil pan. (c) Disconnect the solenoid connector. (d) Remove the shift solenoid valve No. 1 or No. 2. CHECK: (a) Measure the resistance between solenoid connector and body ground. (b) Connect positive ę lead to terminal of the solenoid connector, negative Ĝ lead to the solenoid body. OK: (a) Resistance: 11 − 15 Ω (b) The shift solenoid valve No. 1 or No. 2 makes an operating noise. NG Replace shift solenoid valve No. 1 or No. 2. OK Repair or replace solenoid wire. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−161 DIAGNOSTICS − AUTOMATIC TRANSMISSION DI5KQ−02 DTC P0770 Shift Solenoid E Malfunction (Shift Solenoid Valve SL) SYSTEM DESCRIPTION Line Pressure Drain The ECM uses the signals from the throttle position sensor, air− flow meter and crankshaft position sensor to monitor the engagement condition of the lock−up clutch. Then the ECM compares the engagement condition of the lock−up clutch with the lock−up schedule in the ECM memory to detect mechanical trouble of the shift solenoid valve SL, valve body and torque converter clutch. D00076 DTC No. DTC Detecting Condition Trouble Area Lock−up does not occur when driving in the lock−up range (normal driving at 80 km/h [50 mph]), or lock−up remains ON in the lock−up OFF range (2 trip detection logic) P0770 S Shift solenoid valve SL is stuck open or closed S Valve body blocked up or stuck S Lock−up clutch INSPECTION PROCEDURE 1 Check shift solenoid valve SL operation. PREPARATION: Remove the shift solenoid valve SL from the valve body. CHECK: (a) Applying 490 kPa (5 kgf/cm2, 71 psi) of compressed air, check that the solenoid valve opens. (b) When battery voltage is supplied to the shift solenoid valve, check it does not leak air. Air (+) (−) (+) (−) Q08219 Q08226 D00087 NG Replace shift solenoid valve SL. OK 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−162 DIAGNOSTICS 2 − AUTOMATIC TRANSMISSION Check valve body (See page DI−147). NG Repair or replace valve body. OK Replace torque converter clutch (See page AT−26). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−163 DIAGNOSTICS − AUTOMATIC TRANSMISSION DI5KS−02 DTC P0773 Shift Solenoid E Electrical Malfunction (Shift Solenoid Valve SL) CIRCUIT DESCRIPTION The shift solenoid valve SL is turned ON and OFF by signals from the ECM to control the hydraulic pressure acting on the lock−up relay valve, which then controls operation of the lock−up clutch. Fail Safe Function: If the ECM detects a malfunction, it turns the shift solenoid valve SL OFF. DTC No. P0773 DTC Detecting Condition Trouble Area Open or short in shift solenoid valve SL circuit for 1 time (2 trip detection logic) S Open or short in shift solenoid valve SL circuit S Shift solenoid valve SL S ECM WIRING DIAGRAM Transmission ECM B+ Solenoid Valve SL Y 3 R−L 3 EC2 R−L 8 E4 SL Q07464 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−164 DIAGNOSTICS − AUTOMATIC TRANSMISSION INSPECTION PROCEDURE 1 Measure resistance between terminal SL of ECM and body ground. PREPARATION: Disconnect the connector from the ECM. CHECK: Measure the resistance between terminal SL of the ECM and body ground. OK: Resistance: 11 − 15 Ω SL Q07647 OK Check and replace ECM. NG 2 Check harness and connector between ECM and automatic transmission solenoid connector. PREPARATION: Disconnect the solenoid connector from the transmission. CHECK: Check the harness between terminal SL of the ECM and terminal SL of the automatic transmission solenoid connector. OK: There is no open or short circuit. SL SL Q07649 Q07312 D00088 NG Repair or replace harness or connector. OK 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−165 DIAGNOSTICS 3 − AUTOMATIC TRANSMISSION Check shift solenoid valve SL. Q08222 Q08224 D00083 PREPARATION: (a) Jack−up the vehicle. (b) Remove the oil pan. (c) Disconnect the shift solenoid valve SL connector. (d) Remove the shift solenoid valve SL. CHECK: (a) Measure the resistance between the shift solenoid valve SL connector terminal and its body ground. (b) Connect positive  lead to terminal of the solenoid connector, negative lead to the solenoid body. OK: (a) Resistance: 11 − 15 Ω (b) Shift solenoid valve SL makes operation noise. NG Replace shift solenoid valve SL. OK Check and replace or repair solenoid wire. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−166 DIAGNOSTICS − AUTOMATIC TRANSMISSION DI5KW−02 DTC P1700 Speed Sensor No. 2 Circuit Malfunction (No. 2 Vehicle Speed Sensor) CIRCUIT DESCRIPTION The No. 2 vehicle speed sensor detects the rotation speed of the transmission output shaft and sends signals to the ECM. The ECM determines the vehicle speed based on these signals. An AC voltage is generated in the No. 2 vehicle speed sensor coil as the rotor mounted on the output shaft rotates, and this voltage is sent to the ECM. The gear shift point and lock−up timing are controlled by the ECM based on the signals from this vehicle speed sensor and the throttle position sensor signal. If the No. 2 vehicle speed sensor malfunctions, the ECM uses input signals from the No. 1 vehicle speed sensor as a back−up signal. Rotor Rotor No. 2 Vehicle Speed Sensor No. 2 Vehicle Speed Sensor Q07352 AT5605 DTC No. DTC Detecting Condition P1700 All conditions below are detected 500 times or more continuously (2 trip detection logic) (a) No signal from No. 2 vehicle speed sensor is input to ECM while 4 pulses of No. 1 vehicle speed sensor signal is sent (b) Vehicle speed: 9 km/h (5.6 mph) or more for as least 4 sec. (c) Park/neutral position switch: OFF (Other than P or N position) (d) Transfer position: Other than N position D00084 Trouble Area S Open or short in No. 2 vehicle speed sensor circuit S No. 2 vehicle speed sensor S ECM Reference: Waveform between terminals SP2+ and SP2− when the vehicle speed is approx. 60 km/h (37 mph). 0V 5 V/div. 2 msec./div. AT8761 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−167 DIAGNOSTICS − AUTOMATIC TRANSMISSION WIRING DIAGRAM ECM 5 EC2 V 2 SP2+ E6 V 1 No. 2 Vehicle Speed Sensor 2 4 EC2 V−G V−G 8 SP2− E6 Q07465 INSPECTION PROCEDURE 1 Check vehicle speed value or resistance between terminals SP2+ and SP2− of ECM. SP2+ SP2− Q08227 When using OBD II scan tool or TOYOTA hand−held tester: PREPARATION: (a) Remove the fuse box cover. (b) Connect an OBD II scan tool or TOYOTA hand−held tester to the DLC3. (c) Start the engine and turn the OBD II scan tool or TOYOTA hand−held tester main switch ON. CHECK: Drive the vehicle and read vehicle speed value. OK: Vehicle speed matches tester speed value. When not using OBD II scan tool or TOYOTA hand−held tester: PREPARATION: Disconnect the connector from the ECM. CHECK: Check the resistance between terminals SP2+ and SP2− of the ECM. OK: Resistance: 560 − 680 Ω OK Check and replace ECM. NG 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−168 DIAGNOSTICS 2 − AUTOMATIC TRANSMISSION Check No. 2 vehicle speed sensor. PREPARATION: Remove the No. 2 vehicle speed sensor from the transmission. CHECK: (a) Measure the resistance between terminals 1 and 2 of the vehicle speed sensor. (b) Check the voltage between terminals 1 and 2 of the vehicle speed sensor when a magnet is put close to the front end of the vehicle speed sensor then taken away quickly. OK: (a) Resistance: 560 − 680 Ω (b) Voltage is generated intermittently. HINT: The generated voltage is extremely low. Q08218 D00179 NG Replace No. 2 vehicle speed sensor. OK Check and repair harness and connector between ECM and No. 2 vehicle speed sensor (See page IN−28). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−169 DIAGNOSTICS − AUTOMATIC TRANSMISSION DI5KY−02 DTC P1780 Park/Neutral Position Switch Malfunction CIRCUIT DESCRIPTION The park/neutral position switch detects the shift lever position and sends signals to the ECM. The ECM receives signals (NSW, R, 2 and L) from the park/neutral position switch. When the signal is not sent to the ECM from the park/neutral position switch, the ECM judges that the shift lever is in D position. DTC No. DTC Detection Condition Trouble Area 2 or more switches are ON simultaneously for N, 2 and L positions (2 trip detection logic) When driving under conditions (a), (b) and (c) for 30 sec. or more, the park/neutral position switch is ON (N position) (2 trip detection logic) (a) Vehicle speed: 70 km/h (44 mph) or more (b) Engine speed: 1,500 − 2,500 rpm (c) Engine load: 0.6 g/rev. or more P1780 S Short in park/neutral position switch circuit S Park/neutral position switch S ECM WIRING DIAGRAM W 2 3 4 2 B−L Battery 1 FLAM1 F6 Combination Meter 2 AM1 1 R/B No. 2 2 Y 2 B GAUGE B J4 Ignition Switch 6 EA2 IG1 2 B B−Y 4 AM1 ST1 1 Y B Fuse Block From Battery 6 Park/Neutral Position Switch 2 O IH2 3 Y 4 3 G−R IH2 2 B−R 5 1 S1 1 S2 7 R−B IH1 8 21 B−W IH1 6 11 R 2 L C12 10 C12 4 C12 R−B G−W O 17 G−W L E7 O R−B ECM 16 E7 2 15 E7 R B−W B+ Starter B−W 22 E7 NSW Q08577 D00180 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−170 DIAGNOSTICS − AUTOMATIC TRANSMISSION INSPECTION PROCEDURE 1 Read PNP, REVERSE, 2ND and LOW signals. When using TOYOTA hand−held tester: PREPARATION: (a) Remove the fuse box cover. (b) Connect a TOYOTA hand−held tester to the DLC3. (c) Turn the ignition switch ON and TOYOTA hand−held tester main switch ON. CHECK: Shift lever into the P, R, N, 2 and L positions, and read the PNP, REVERSE, 2 and L signals on the TOYOTA hand−held tester. OK: ON (+) R (−) NSW BE3840 Q08479 L 2 D00090 Shift position Signal 2 2ND OFF → ON L LOW OFF → ON R REVERSE OFF → ON P, N PNP SW OFF → ON When not using TOYOTA hand−held tester: PREPARATION: Turn the ignition switch ON. CHECK: Measure the voltage between terminals NSW, 2 and L of ECM and body ground when the shift lever is shifted to the following positions. OK: Position NSW − R− 2− L− Body ground Body ground Body ground Body ground P, N Below 1.5 V Below 1.5 V Below 1.5 V Below 1.5 V R 9 − 14 V 7.5 − 14 V* Below1.5 V Below1.5 V D 9 − 14 V Below 1.5 V Below 1.5 V Below 1.5 V 2 9 − 14 V Below 1.5 V 7.5 − 14 V L 9 − 14 V Below 1.5 V Below 1.5 V 7.5 − 14 V Below 1.5 V *: The voltage will drop slightly due to lighting up of the back up light. OK Check and replace ECM. NG 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−171 DIAGNOSTICS 2 − AUTOMATIC TRANSMISSION Check park/neutral position switch. PREPARATION: (a) Jack up the vehicle. (b) Remove the park/neutral position switch connector. CHECK: Check the continuity between each terminal shown below when the shift lever is moved to each position. OK: Q07657 Shift Position Terminal No. to continuity Terminal No. to continuity P 4−7 5−6 D00109 NG R 4−8 − N 4 − 10 5−6 D 4−9 − 2 2−4 − L 3−4 − Replace park/neutral position switch. OK Repair or replace harness and connector between battery and park/neutral position switch, and park/neutral position switch and ECM (See page IN−28). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−172 DIAGNOSTICS − AUTOMATIC TRANSMISSION DI5L0−02 O/D Cancel Signal Circuit CIRCUIT DESCRIPTION While driving with cruise control activated, in order to minimize gear shifting and provide smooth cruising on an uphill, overdrive may be prohibited temporarily in some conditions. The cruise control ECU sends O/D cut signals to the ECM as necessary and the ECM cancels overdrive shifting until these signals are discontinued. (For details, see the Cruise Control section, page DI−292) WIRING DIAGRAM Cruise Control ECU ECM B+ OD 9 G−O 18 OD1 E7 Q07467 INSPECTION PROCEDURE 1 Check voltage between terminal OD1 of ECM and body ground. PREPARATION: Turn the ignition switch ON. CHECK: Measure the voltage between terminal OD1 of the ECM and body ground. OK: Voltage: 9 − 14 V ON (−) (+) BE3840 Q07658 OD1 D00091 OK Proceed to next circuit inspection shown on problem symptoms table (See page DI−147). NG 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−173 DIAGNOSTICS 2 − AUTOMATIC TRANSMISSION Check voltage between terminal OD of cruise control ECU harness side connector and body ground. PREPARATION: (a) Disconnect the cruise control ECU connector. (b) Turn ignition switch ON. CHECK: Measure the voltage between terminal OD of the cruise control ECU harness side connector and body ground. OK: Voltage: 9 − 14 V ON OD BE3840 Q07660 D00015 OK Check and replace cruise control ECU. NG 3 Check harness and connector between cruise control ECU and ECM (See page IN−28). NG Repair or replace wire harness or connector. OK Check and replace ECM. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−174 DIAGNOSTICS − AUTOMATIC TRANSMISSION DI5L3−03 O/D Main Switch & O/D OFF Indicator Light Circuit CIRCUIT DESCRIPTION The O/D main switch contacts go off when the switch is pushed in and come on when it is pushed once again. In O/D main switch OFF position, the O/D OFF indicator lights up, and the ECM prohibits shifting to O/D. WIRING DIAGRAM 6 O/D OFF Indicator Light Fuse Block (Combination Meter) Ignition Switch J1 8 9 GAUGE Y B B−Y Y P−L C12 C12 2 3 A A 4 1 EA2 ECM 19 OD2 E7 B+ P−L B 22 ID2 2 AM1 2 P−L R/B No. 2 2 1 O/D Main Switch* 2 R/B No. 2 W 2 3 4 2 B−L *: O/D Main switch Contact go off with switch pushed in. Contact go on with switch once again. Fuse Block FL AM1 E6 4 W−B Battery BF Q08582 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−175 DIAGNOSTICS − AUTOMATIC TRANSMISSION INSPECTION PROCEDURE O/D OFF indicator light does not light up: 1 Check operation of O/D main switch. CHECK: (a) Turn the ignition switch ON. (b) Check the O/D OFF indicator light when the O/D main switch is pushed in to ON. OK: O/D OFF indicator light goes off CHECK: Check the O/D OFF indicator light when the O/D main switch is pushed again to OFF. OK: O/D OFF indicator light lights up ON OFF ON BE3840 D00077 D00092 NG Go to step 4. OK 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−176 DIAGNOSTICS 2 − AUTOMATIC TRANSMISSION Check OVRDRIVE CUT SW2 signal. When using TOYOTA hand−held tester: PREPARATION: (a) Remove the fuse box cover. (b) Connect a TOYOTA hand−held tester to the DLC3. (c) Turn the ignition switch ON and TOYOTA hand−held tester main switch ON. CHECK: Read the OVRDRIVE CUT SW2 signal on the TOYOTA hand− held tester. OK: OVRDRIVE CUT SW2 Signal OFF O/D OFF (pushed out) ON When not using TOYOTA hand−held tester: PREPARATION: Turn the ignition switch ON. CHECK: Check the voltage between terminal OD2 of the ECM and body ground. OK: ON OD2 BE3840 Q08230 O/D Main Switch O/D ON (pushed in) D00093 OK O/D Main Switch Voltage O/D ON 9 − 14 V O/D OFF Below 3 V Proceed to next circuit inspection shown on problem symptoms table (See page DI−147). NG 3 Check harness and connector between O/D OFF indicator light and ECM (See page IN−28). NG Repair or replace harness or connector. OK Check and replace ECM. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−177 DIAGNOSTICS 4 − AUTOMATIC TRANSMISSION Check O/D main switch. CHECK: (a) Disconnect the O/D main switch connector. (b) Measure the resistance between terminals 2 and 4 of the O/D main switch connector. OK: O/D Main Switch Resistance ON ∞ Ω 〈open) OFF 0 Ω (continuity) Q08233 NG Replace O/D main switch. OK Check and replace the combination meter (See page BE−32). O/D OFF indicator light remains ON: 1 Check O/D main switch. CHECK: (a) Disconnect the O/D main switch connector. (b) Measure the resistance between terminals 2 and 4 of the O/D main switch connector. OK: O/D Main Switch Resistance ON ∞ Ω 〈open) OFF 0 Ω (continuity) Q08233 NG Replace O/D main switch. OK 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−178 DIAGNOSTICS 2 − AUTOMATIC TRANSMISSION Check harness and connector between O/D OFF indicator light and O/D main switch, and O/D OFF indicator light and ECM (See page IN−28). NG Repair or replace harness or connector. OK Check and replace ECM. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−179 DIAGNOSTICS − AUTOMATIC TRANSMISSION DI5L6−03 Pattern Select Switch Circuit (PWR Mode Switch) CIRCUIT DESCRIPTION The ECM memory contains the shift programs for the NORMAL and POWER patterns, 2 position, L position and the lock−up patterns. Following the programs corresponding to the signals from the pattern select switch, the park/neutral position switch and other various sensors, the ECM switches the solenoid valves ON and OFF, and control the transmission gear change and the lock−up clutch operation. WIRING DIAGRAM Pattern Select Switch* (PWR Mode Switch) B−W 3 6 P−B IG1 Fuse Block J6 15 EGU−IG B−Y B−W B−W ID2 3 B B 2 1 16 ID2 P−B P−B 20 PWR E7 13 C12 Ignition Switch AM1 B ECM PWR Indicator Light (Combination Meter) 4 6 EA2 B 2 R/B No. 2 2 AM1 1 2 W 2 R/B No. 2 4 3 2 B−L *: Pattern Select Switch (PWR Mode Switch) When the PWR mode switch is pushed in, the switch is contacted and the PWR mode is celected. To cancel the PWR mode, push the PWR mode switch onec again. Fuse Block FL AM1 F6 Battery Q08584 INSPECTION PROCEDURE 1 Check operation of PWR indicator light. PREPARATION: Check if the PWR indicator light normally when the PWR mode switch is set to NORM and PWR position. NG Check and repair PWR indicator light. OK 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−180 DIAGNOSTICS 2 − AUTOMATIC TRANSMISSION Check PATTERN SEL SW signal. When using TOYOTA hand−held tester: PREPARATION: (a) Remove the fuse box cover. (b) Connect a TOYOTA hand−held tester to the DLC3. (c) Turn the ignition switch ON and TOYOTA hand−held tester main switch ON. CHECK: Read the PWR signal on the TOYOTA hand−held tester. OK: PATTERN SEL SW Signal PWR ON NORM OFF When not using TOYOTA hand−held tester: PREPARATION: Turn the ignition switch ON. CHECK: Measure the voltage between terminal PWR of the ECM connector and body ground when the PWR mode switch is set to the PWR (POWER) position and NORM (NORMAL) position. OK: ON PWR BE3840 Q08229 PWR Mode Switch D00094 PWR Mode Switch Voltage PWR 7.5 − 14 V NORM Below 1.5 V HINT: The ECM uses the normal pattern signal if the power signal is not input. OK Proceed to next circuit inspection shown on problem symptoms table (See page DI−147). NG 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−181 DIAGNOSTICS 3 − AUTOMATIC TRANSMISSION Check PWR mode switch. PREPARATION: Disconnect the pattern select switch connector. CHECK: Check the resistance between terminals of the pattern select switch connector when the PWR mode switch is set to PWR and NORM positions. OK: Q08235 NG PWR Mode Switch Resistance PWR 0 Ω (continuity) NORM ∞ Ω (open) Replace pattern select switch. OK 4 Check harness and connector between battery and pattern select switch, and pattern select switch and ECM (See page IN−28). NG Repair or replace harness or connector. OK Check and replace ECM. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−182 − DIAGNOSTICS AUTOMATIC TRANSMISSION DI5L8−03 Pattern Select Switch Circuit (2nd Start Switch) & 2nd Start Switch Indicator Light Circuit CIRCUIT DESCRIPTION When 2nd start mode is selected with the pattern select switch, the ECM controls the solenoid valves and the transmission starts from 2nd gear. In D position, the transmission automatically shifts up through 3rd to O/D as usual. In 2nd position, the transmission is held in 2nd gear. WIRING DIAGRAM 2nd STRT Indicator Light ECM Fuse Block (Combination Meter) Ignition Switch J1 12 R−W 12 R−W 18 HI GAUGE Y Y 9 AM1 IG1 B−Y C12 C12 IH2 E4 A 4 2 1 3 A Y A 1 IG3 B W 2 Pattern Select Switch* (2nd Start Switch) 6 EA2 5 BR B 2 R/B No. 2 2 AM1 1 2 W 2 R/B No. 2 4 3 ID3 2 O 11 IH2 O 3 HOLD E4 Fuse Block B−L FL AM1 F6 Battery *: Pattern Select Switch (2nd Start Switch) When the 2nd start switch is pushed, the switch is contacted and the 2nd mode is selected. To cancel the 2nd start, push the 2nd start swtch once again. The 2nd start is automatically cancelled out when the ignition switch is turned OFF. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Q08580 Brought to you by BirfMark DI−183 DIAGNOSTICS − AUTOMATIC TRANSMISSION INSPECTION PROCEDURE 1 Check operation of 2nd start switch. ON BE3840 Q07359 D00023 CHECK: (a) Turn the ignition switch ON. (b) Check the ”2nd STRT” indicator light when the 2nd start switch is pushed in to ON. OK: ”2nd STRT” indicator light lights up. CHECK: Check the ”2nd STRT” indicator light when the 2nd start switch is pushed again, or PWR mode switch is pushed into OFF. OK: ”2nd STRT” indicator light goes off. When PWR mode switch is pushed in to ON, ”2nd STRT” indicator light goes off, and ”PWR” indicator light lights up. OK Proceed to next circuit inspection shown on problem symptoms table (See page DI−147). NG Replace 2nd start indicator bulb. NG 2 Check 2nd start indicator bulb. OK 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−184 DIAGNOSTICS 3 − AUTOMATIC TRANSMISSION Check 2nd start switch. PREPARATION: Disconnect the pattern select switch connector. CHECK: Check the resistance between terminals 2 and 5 of the pattern select switch connector when the pattern select switch is set to 2nd start switch ON and OFF. OK: Q08234 NG 2nd Start Switch Resistance ON 0 Ω (continuity) OFF ∞ Ω (open) Replace pattern select switch. OK 4 Check voltage between terminals HOLD and HI of ECM and body ground. PREPARATION: (a) Turn ignition switch ON. (b) Disconnect the connector from the ECM. CHECK: Check the voltage between terminal HOLD of the ECM and body ground when the select switch is set to 2nd start switch ON and OFF. OK: ON HI HOLD D00096 2nd Start Switch Voltage ON 9 − 14 V OFF Below 1.5 V CHECK: Check the voltage between terminal HI of the ECM and body ground. OK: Voltage: 7.5 − 14 V OK Check and replace ECM. NG Check and replace harness and connector between battery and patten select switch, pattern select switch and ECM, battery and 2nd start indicator light, and 2nd start indicator light and ECM (See page IN−28). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI-185 DIAGNOSTICS - AUTOMATIC TRANSMISSION DI5L8-02 Pattern Select Switch Circuit (2nd Start Switch) & 2nd Start Switch Indicator Light Circuit CIRCUIT DESCRIPTION When 2nd start mode is selected with the pattern select switch, the ECM controls the solenoid valves and the transmission starts from 2nd gear. In D position, the transmission automatically shifts up through 3rd to O/D as usual. In 2nd position, the transmission is held in 2nd gear. WIRING DIAGRAM B 2nd STRT Indicator Light ECM Fuse Block (Combination Meter) Ignition Switch J1 A 9 12 18 HI 12 4 AM1 IG1 2 1 GAUGE 3 A R-W R-W C12 C12 IH2 E4 B-Y Y Y AY 1 IG3 W 2 (*) Pattern Select Switch (2nd Start Switch) 11 5 BR O IG3 IL2 B 6 EA2 2 R/B No.2 2 AM1 1 2 W 2 R/B No.2 4 3 2 O 3 HOLD E4 Fuse Block B-L FL AM1 F6 Battery Q08580 (*) Pattern Select Switch (2nd Start Switch) When the 2nd start switch is pushed, the switch is contacted and the 2nd mode is selected. To cancel the 2nd start, push the 2nd start switch once again. The 2nd start is automatically cancelled out when the ignition switch is turned OFF. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI-186 DIAGNOSTICS - AUTOMATIC TRANSMISSION INSPECTION PROCEDURE 1 Check operation of 2nd start switch. ON BE3840 Q07359 D00023 CHECK: (a) Turn the ignition switch ON. (b) Check ”2nd STRT” indicator light when 2nd start switch is pushed in to ON. OK: ”2nd STRT” indicator light lights up. CHECK: Check ”2nd STRT” indicator light when 2nd start switch is pushed again, or PWR mode switch is pushed into OFF. OK: ”2nd STRT” indicator light goes off. When PWR mode switch is pushed in to ON, ”2nd STRT” indicator light goes off, and ”PWR” indicator light lights up. OK Proceed to next circuit inspection shown on matrix chart (See page DI-150 ). NG Replace 2nd start indicator bulb. NG 2 Check 2nd start indicator bulb. OK 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI-187 DIAGNOSTICS 3 - AUTOMATIC TRANSMISSION Check 2nd start switch. PREPARATION: Disconnect the pattern select switch connector. CHECK: Check continuity between terminals 2 and 5 of pattern select switch connector when pattern select switch is set to 2nd start switch ON and OFF. OK: Q08234 2nd start switch Specified condition Press continuously ”2nd” switch 0 Ω (Continuity) Release ”2nd” switch ∞ Ω (open) NG Replace pattern select switch. OK 4 Check voltage between terminals HOLD and HI of ECM and body ground. PREPARATION: (a) Turn ignition switch ON. (b) Disconnect the connector of ECM. CHECK: Check voltage between terminal HOLD of ECM and body ground when the select switch is set to 2nd start switch ON and OFF. OK: ON HI HOLD D00096 2nd start switch Voltage ON 9 - 14 V OFF Below 1.5 V CHECK: Check voltage between terminal HI of ECM and body ground. OK: Voltage: 7.5 - 14 V OK Check and replace the ECM. NG Check and replace harness and connector between battery and patten select switch, pattern select switch and ECM, battery and 2nd start indicator light , 2nd start indicator light and ECM (See page IN-27 ). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−188 DIAGNOSTICS − ANTI−LOCK BRAKE SYSTEM ANTI−LOCK BRAKE SYSTEM DI5LT−02 HOW TO PROCEED WITH TROUBLESHOOTING Troubleshoooting in accordance with the procedure on the following pages. Vehicle Brought to Workshop Items inside are titles of pages in this manual, with the page number in the bottom portion. See the indicated pages for detailed explanations. 1 Customer Problem Analysis P. DI−189 2 Check and Clear DTC (Pre−check) P. DI−190 3 Symptom does not occur Problem Symptom Confirmation 4 Symptom Simulation P. IN−18 7 Problem Symptoms Table P. DI−200 Symptom occurs 5 Normal code DTC Check P. DI−190 Malfunction code 6 8 DTC Chart P. DI−196 Circuit Inspection 9 Sensor Check Check for Fluid Leakage P. DI−237 P. DI−201 − DI−235 Identification of Problem 10 11 Repair Confirmation Test End Step 8: Diagnostic steps permitting the use of the TOYOTA hand−held tester or TOYOTA breake−out−box. 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 355 Brought to you by BirfMark DI−189 − DIAGNOSTICS ANTI−LOCK BRAKE SYSTEM DI5LU−01 CUSTOMER PROBLEM ANALYSIS CHECK ABS Check Sheet Inspector’s : Name Registration No. Registration Year Customer’s Name / / Frame No. Date Vehicle Brought In / Date Problem First Occurred / Frequency Problem Occurs km miles Odometer Reading / Continuous / Intermittent ( times a day) ABS does not operate. Symptoms DTC Check ABS does not operate efficiently. ABS Warning Light Abnormal Remains ON Does not Light Up 1st Time Normal Code Malfunction Code (Code ) 2nd Time Normal Code Malfunction Code (Code ) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−190 DIAGNOSTICS − ANTI−LOCK BRAKE SYSTEM PRE−CHECK 1. (a) DI5LV−02 DIAGNOSIS SYSTEM Check the indicator. When the ignition switch is turned ON, check that the ABS warning light goes on for 3 seconds. HINT: S R04751 S (b) Short Pin If the indicator check result is not normal, proceed to troubleshooting for the ABS warning light circuit (See page DI−230). When the transfer is in L position (center differential lock), the ABS does not operate and the ABS warning light stays ON. Check the DTC. (1) Confirm that the center differential is free. (2) Disconnect the short pin from the DLC1. DLC1 F00006 (3) Using SST, connect terminals Tc and E1 of the DLC1. SST 09843−18020 (4) Turn the ignition switch ON. (5) Read the DTC from the ABS warning light on the combination meter. Tc E1 HINT: S DLC1 F00007 If no code appears, inspect the diagnostic circuit or ABS warning light circuit (See page DI−233 or DI−230). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−191 DIAGNOSTICS − ANTI−LOCK BRAKE SYSTEM As an example, the blinking patterns for normal code and codes 11 and 21 are shown in the illustration. (6) Code are explained in the code table on page DI−196. (7) After completing the check, disconnect terminals Tc and E1, and turn off the display. If 2 or more malfunctions are indicated at the same time the lowest numbered DTC will be displayed 1st. S Normal Code 2 sec. 0.25 sec. 0.25 sec. ON OFF Code 11 and 21 0.5 sec. 1.5 sec. 4 sec. 0.5 sec. 2.5 sec. ON OFF Code 11 Code 21 R01346 (c) BR1804 Short Pin Clear the DTC. (1) Confirm that the center differential is free. (2) Using SST, connect terminals Tc and E1 of the DLC1 and remove the short pin from the DLC1. SST 09843−18020 (3) Turn the ignition switch ON. (4) Clear the DTC stored in ECU by depressing the brake pedal 8 or more times within 3 seconds. (5) Check that the warning light shows the normal code. (6) Remove the SST from the terminals of the DLC1. SST 09843−18020 (7) Connect the short pin to the DLC1. HINT: Cancellation can also be done by removing the ECU−B fuse, but in this case, other memory systems will also be cancelled out. DLC1 F00006 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−192 DIAGNOSTICS Interface Box Vehicle TOYOTA Hand−held Harness Tester TOYOTA Break−out−box N09348 (d) (a) Ts Tc DLC1 F00007 0.25 sec. 0.25 sec. ON OFF BR3904 ANTI−LOCK BRAKE SYSTEM Using TOYOTA break−out−box and TOYOTA hand−held tester, measure the ECU terminal values. (1) Hook up the TOYOTA hand−held tester and TOYOTA break−out−box to the vehicle. (2) Read the ECU input/output values by following the prompts on the tester screen. HINT: TOYOTA hand−held tester has a ”Snapshot ” function. This records the measured values and is effective in the diagnosis of intermittent problems. Please refer to the TOYOTA hand−held tester/TOYOTA break out−box operators manual for further details. 2. E1 − SPEED SENSOR SIGNAL AND DECELERATION SENSOR CHECK Check the speed sensor signal. (1) Conform that the center differential is free. (2) Turn the ignition switch OFF. (3) Using SST, connect terminals Ts and E1 of the DLC1. SST 09843−18020 (4) Start the engine. (5) Check that the ABS warning light blinks. HINT: If the ABS warning light does not blink, inspect the ABS warning light circuit (See page DI−230). (6) Drive vehicle straight forward. HINT: Drive vehicle faster than 45 km/h (28 mph) for several seconds. (7) Stop the vehicle. (8) Using SST, connect terminals Tc and E1 of the DLC1. SST 09843−18020 (9) Read the number of blinks of the ABS warning light. HINT: See the list of DTC on page DI−190. If every sensor is normal, a normal code is output (A cycle of 0.25 sec. ON and 0.25 sec. OFF is repeated). If 2 or more malfunction are indicated at the same time, the lowest numbered code will be displayed 1st. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−193 DIAGNOSTICS − ANTI−LOCK BRAKE SYSTEM Malfunction Code (Example Code 72, 76) 7 2 7 6 ON OFF 1.5 sec. 0.5 sec. 0.5 sec. 0.5 sec. 4 sec. 2.5 sec. 0.5 sec. Repeat BR3893 (10) After doing the check, disconnect terminals Ts and E1, Tc and E1 of the DLC1, and turn the ignition switch OFF. (b) E1 Ts Deceleration sensor detection point check. (1) Confirm that the center differential is free. (2) Turn the ignition switch OFF. (3) Using SST, connect terminals Ts and E1 of the DLC1. SST 09843−18020 (4) Start the engine. DLC1 F00007 (5) Check that the ABS warning light blinks. HINT: If the ABS warning light does not blink, inspect the ABS warning light circuit (See page DI−230). 0.13 sec. ON OFF 3 sec. 0.13 sec. R05599 (6) 860 " 30 mm 33.86 " 1.18 in. R05037 Jack up the rear side of the vehicle slowly. HINT: When measuring the height, measure at the center of the lower body of the vehicle. (7) Check that the warning light blinks. If the warning light turns on, inspect the deceleration sensor installation. If the sensor installation is OK, replace the deceleration sensor. (8) Jack down the vehicle slowly. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−194 DIAGNOSTICS (9) 780 " 30 mm 30.71 " 1.18 in. R05038 0.13 sec. ON − ANTI−LOCK BRAKE SYSTEM Jack up the front side of the vehicle slowly, as shown. HINT: When measuring the height, measure at the center of the lower body of the vehicle. (10) Check that the warning light blinks. If the warning light turns on, inspect the deceleration sensor installation. If the sensor installation is OK, replace the deceleration sensor. (11) Jack down the vehicle slowly. (c) Deceleration sensor operation check. (1) Drive the vehicle straight ahead at about 20 km/h (12.4 mph) or more, lightly depress the brake pedal. (2) Check that there is no change in the warning light pattern. OFF 0.13 sec. BR1865 (3) Braking 0.13 sec. (4) (5) 0.13 sec. Drive the vehicle straight ahead at about 20 km/h (12.4 mph) or more, and depress the brake pedal moderately. Check that the warning light turns on while braking. Drive the vehicle straight ahead at about 20 km/h (12.4 mph) or more, and depress the brake pedal strongly. R05596 (6) 0.13 sec. 0.13 sec. Braking R05597 Check that the warning light pattern changes while braking, as shown. If the operation is not as specified, inspect the deceleration sensor installation. If the sensor installation is OK, replace the deceleration sensor. (7) Stop the vehicle and turn the ignition switch OFF. (8) Remove SST from the terminals Ts and E1 of the DLC1. SST 09843−18020 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−195 DIAGNOSTICS (d) − ANTI−LOCK BRAKE SYSTEM Check the DTC of speed sensor function. Code No. Diagnosis Trouble Area Low output voltage of right front speed sensor S Right front speed sensor S Sensor installation S Sensor rotor S Sensor wire harness Low output voltage of left front speed sensor S Left front speed sensor S Sensor installation S Sensor rotor S Sensor wire harness Low output voltage of right rear speed sensor S Right rear speed sensor S Sensor installation S Sensor rotor S Sensor wire harness 74 Low output voltage of left rear speed sensor S Left rear speed sensor S Sensor installation S Sensor rotor S Sensor wire harness 75 Abnormal change in output voltage of right front speed sensor S Right front speed sensor rotor S Sensor wire harness 76 Abnormal change in output voltage of left front speed sensor S Left front speed sensor rotor S Sensor wire harness 77 Abnormal change in output voltage of right rear speed sensor S Right rear speed sensor rotor S Sensor wire harness 78 Abnormal change in output voltage of left rear speed sensor S Left rear speed sensor rotor S Sensor wire harness 79 Deceleration sensor is faulty S Deceleration sensor S Sensor installation 71 72 73 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−196 DIAGNOSTICS − ANTI−LOCK BRAKE SYSTEM DI5LW−03 DIAGNOSTIC TROUBLE CODE CHART NOTICE: When removing the part, turn the ignition switch OFF. HINT: S Using SST 09843−18020, connect the terminals Tc and E1, and remove the short pin. S If any abnormality is not found when inspection parts, inspect the ECU. If a malfunction code is displayed during the DTC check, check the circuit listed that the code. For details of each code, turn to the page referred to under the ”See page” for respective ”DTC No.” in the DTC chart. DTC No. (See page) Detection Item Trouble Area 11 (DI−201) Open circuit in ABS control (solenoid) relay circuit S ABS control (solenoid) relay S Open or short in ABS control (solenoid) relay circuit 12 (DI−201) Short circuit in ABS control (solenoid) relay circuit S ABS control (solenoid) relay S B+ short in ABS control (solenoid) relay circuit 13 (DI−204) Open circuit in ABS control (motor) relay circuit S ABS control (motor) relay S Open or short in ABS control (motor) relay circuit 14 (DI−204) Short circuit in ABS control (motor) relay circuit S ABS control (motor) relay S B+ short in ABS control (motor) relay circuit 21 (DI−207) Open or short circuit in 3−position solenoid circuit for right front wheel S ABS actuator S Open or short in SFR circuit 22 (DI−207) Open or short circuit in 3−position solenoid circuit for left front wheel S ABS actuator S Open or short in SFLcircuit 23 (DI−207) Open or short circuit in 3−position solenoid circuit for rear wheel S ABS actuator S Open or short in SRR circuit 31 (DI−210) Right front wheel speed sensor signal malfunction 32 (DI−210) Left front wheel speed sensor signal malfunction 33 (DI−210) Right rear wheel speed sensor signal malfunction 34 (DI−210) Left rear wheel speed sensor signal malfunction 35 (DI−210) Open circuit in left front or right rear speed sensor circuit S Open in left front or right rear speed sensor circuit 36 (DI−210) Open circuit in right front or left rear speed sensor circuit S Open in right front or left rear speed sensor circuit 41 (DI−215) Low battery positive voltage or abnormally high battery positive voltage S Battery S IC regulator S Open or short in power source circuit 43 (DI−218) Malfunction in deceleration sensor S Deceleration sensor S Wire harness for deceleration sensor circuit 44 (DI−219) Open or short in deceleration sensor circuit S Deceleration sensor S Open or short in deceleration sensor circuit 48 (DI−221) Open or short circuit in center differential lock circuit Center differential is locking S Center differential lock S Center differential lock circuit S Right front, left front, right rear and left rear speed sensor S Open or short in each speed sensor circuit S Senser rotor 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−197 DIAGNOSTICS 51 (DI−224) Always ON (DI−225) − ANTI−LOCK BRAKE SYSTEM Pump motor is locked Open in pump motor ground S ABS pump motor Malfunction in ECU IG power source circuit S Battery S IC regulator S Open or short in power source circuit S ECU 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−198 DIAGNOSTICS − ANTI−LOCK BRAKE SYSTEM DI5LX−02 PARTS LOCATION Rear Speed Sensor ABS Warning Light Deceleration Sensor DLC1 Front Speed Sensor ABS Relay Rear Speed Sensor Rotor ABS ECU Stop Light Switch Front Speed Sensor Rotor ABS Actuator W03004 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−200 DIAGNOSTICS − ANTI−LOCK BRAKE SYSTEM DI5LZ−03 PROBLEM SYMPTOMS TABLE If a normal code is displayed during the DTC check but the problem still occurs, check the circuits for each problem symptom in the order given in the table below and proceed to the relevant troubleshooting page. Symptoms Suspected Area See page ABS does not operate Only when 1 − 4 are all normal and the problem is still occurring, replace the ABS ECU 2. Check the DTC reconfirming that the normal code is output 3. IG power source circuit 4. Speed sensor circuit 5. Check the ABS actuator with a checker If abnormal, check the hydraulic circuit for leakage (See page DI−237) ABS does not operate efficiently Only when 1 − 4 are all normal and the problem is still occurring, replace the ABS ECU 1. Check the DTC reconfirming that the normal code is output 2. Speed sensor circuit 3. Stop light switch circuit 4. Check the ABS actuator with a checker If abnormal, check the hydraulic circuit for leakage (See page DI−237) ABS warning light abnormal 1. ABS warning light circuit 2. ABS ECU DI−230 − DTC check cannot be done Only when 1 and 2 are all normal and the problem is still occurring, replace the ABS ECU 1. ABS warning light circuit 2. Tc terminal circuit DI−230 DI−233 Speed sensor signal check cannot be done 1. Ts terminal circuit 2. ABS ECU DI−235 − 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 DI−190 DI−215 DI−210 BR−53 DI−190 DI−210 DI−228 BR−53 Brought to you by BirfMark DI−201 DIAGNOSTICS − ANTI−LOCK BRAKE SYSTEM DI5M0−02 CIRCUIT INSPECTION DTC 11, 12 ABS Control (Solenoid) Relay Circuit CIRCUIT DESCRIPTION This relay supplies power to each ABS solenoid. After the ignition switch is turned ON, if the initial check is OK, the relay goes on. DTC No. DTC Detecting Condition Trouble Area 11 Conditions (1) and (2) continue for 0.2 sec. or more: 1. ABS control (solenoid) relay terminal (SR) voltage: Battery positive voltage 2. (2) ABS control (solenoid) relay monitor terminal (AST) voltage: 0 V S ABS control (solenoid) relay S Open or short in ABS control (solenoid) relay circuit 12 Conditions 1 and 2 continue for 0.2 sec. or more: 1. ABS control (solenoid) relay terminal (SR) voltage: 0V 2. ABS control (solenoid) relay monitor terminal (AST) voltage: Battery positive voltage S ABS control (solenoid) relay S B+ short in ABS control (solenoid) relay circuit Fail safe function: If trouble in the ABS control (solenoid) relay circuit, the ECU cuts off current to the ABS control (solenoid) relay and prohibits ABS control. WIRING DIAGRAM B−W R/B No. 2 1 A6 Motor EA3 1 Relay 2 W−B 2 3 A7 W A13 G−Y A6 Solenoid Relay 1 G−B A7 6 A7 3 2 A6 A7 5 4 B−L B−R 3 A4 A4 4 DLC1 B−L 2 23 A6 2 R/B No. 2 12 V ABS Control Relay 4 G 2 B−W 1 ABS ECU B−W EA3 B−W ABS 2 2 B−W MR 24 R− A13 12 V 11 SR A13 ABS ECU AM1 F6 1 2 W−B 1 A5 A4 A5 W−B Battery ID ABS Actuator 5 L−Y L−W 18 AST A13 A13 MT 6 W02192 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−202 DIAGNOSTICS − ANTI−LOCK BRAKE SYSTEM INSPECTION PROCEDURE 1 Check voltage between terminals A7−2 and A7−6 of ABS control relay connector. PREPARATION: Disconnect the ABS control relay connector. CHECK: Measure the voltage between terminals A7−2 and A7−6 of the ABS control relay harness side connector. OK: Voltage: 10 − 14 V LOCK (−) 2 A7 (+) 6 BE6653 R14203 F00001 NG Check and repair harness or connector. OK 2 Check continuity between terminals A7−5 and A4−4, A4−4 and A5−2, and A5−2 and A13−18. A7 ABS Control Relay 5 A4 A4 ABS Actuator 4 A5 A5 PREPARATION: Disconnect the 2 connectors from the ABS actuator. CHECK: Check the continuity between terminals A7−5 and A4−4, A4−4 and A5−2, and A5−2 and A13−18. OK: Continuity HINT: There is a resistance of 4 ∼ 6 Ω between terminals A4−4 and A5−2. 2 A13 ABS ECU 18 R00888 NG Repair or replace harness or ABS actuator. OK 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−203 DIAGNOSTICS 3 − ANTI−LOCK BRAKE SYSTEM Check ABS control (solenoid) relay. Continuity Open 2 A7 A6 3 CHECK: Check the continuity between each terminal of the ABS control (solenoid) relay. OK: 1 5 6 Continuity Terminals A7−1 and A6−3 Continuity (Reference value aprox. 80 Ω) Terminals A7−5 and A7−6 Continuity Terminals A7−2 and A7−5 Open R14139 CHECK: (a) Apply battery positive voltage between terminals A7−1 and A6−3. (b) Check the continuity between each terminal of the ABS control (solenoid) relay. OK: Continuity (+) (−) A6 2 3 6 A7 1 5 Open Terminals A7−5 and A7−6 Open Terminals A7−2 and A7−5 Continuity R14140 NG Replace ABS control relay. OK 4 Check for open and short in harness and connector between ABS control (solenoid) relay and ABS ECU (See page IN−28). NG Repair or replace harness or connector. OK If same code is still output after DTC is deleted, check contact condition of each connection. If connections are normal, ECU may be defective. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−207 DIAGNOSTICS − ANTI−LOCK BRAKE SYSTEM DI5M2−02 DTC 21, 22, 23 ABS Actuator Solenoid Circuit CIRCUIT DESCRIPTION This solenoid goes on when signals are received from the ECU and controls the pressure acting on the wheel cylinders thus controlling the braking force. DTC No. DTC Detecting Condition Trouble Area 21 Conditions 1 through 3 continue for 0.05 sec. or more: 1. ABS control (solenoid) relay terminal (SR) voltage: Battery positive voltage 2. Voltage of ABS ECU terminal AST: Battery positive voltage 3. When power transistor of ECU is ON, voltage of terminal SFR is 0 V or battery positive voltage S ABS actuator S Open or short in SFR circuit 22 Conditions 1 through 3 continue for 0.05 sec. or more: 1. ABS control (solenoid) relay terminal (SR) voltage: Battery positive voltage 2. Voltage of ABS ECU terminal AST: Battery positive voltage 3. When power transistor of ECU is ON, voltage of terminal SFL is 0 V or battery positive voltage S ABS actuator S Open or short in SFL circuit 23 Conditions 1 through 3 continue for 0.05 sec. or more: 1. ABS control (solenoid) relay terminal (SR) voltage: Battery positive voltage 2. Voltage of ABS ECU terminal AST: Battery positive voltage 3. When power transistor of ECU is ON, voltage of terminal SRR is 0 V or battery positive voltage S ABS actuator S Open or short in SRR circuit Fail safe function: If trouble occurs in the actuator solenoid circuit, the ECU cuts off current to the ABS control (solenoid) relay and prohibits ABS control. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−208 DIAGNOSTICS − ANTI−LOCK BRAKE SYSTEM WIRING DIAGRAM B−W 2 ABS 1 EA3 1 ABS ECU B−W EA3 B−W 2 R/B No. 2 2 B−W 1 A6 ABS Control Relay 4 A6 Motor Relay 2 B−W W−B 2 W 3 A6 A7 Solenoid 1Relay A7 6 A7 DLC1 2 2 3 R/B No. 2 A6 3 2 5 BL B−R 4 A7 A4 A4 4 1 A5 A5 B−L F6 1 AM1 A5 W−B 4 3 L LG L−R 1 SFR Monitor A13 13 A13 26 A13 SFL SRR 1 A4 ABS ECU W−B ID Battery ABS ECU ABS Actuator W02193 INSPECTION PROCEDURE 1 Check ABS actuator solenoid. LOCK 3 A5 1 A4 4 4 7 F00026 PREPARATION: Disconnect the 2 connectors from the ABS actuator. CHECK: Check the continuity between terminals A4 − 4 and A5−1, 3, 4 of the ABS actuator connector. OK: Continuity HINT: Resistance of each solenoid coil is 0.8 − 1.6 Ω NG Replace ABS actuator. OK 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−209 DIAGNOSTICS 2 − ANTI−LOCK BRAKE SYSTEM Check for open and short in harness and connector between ABS ECU and actuator (See page IN−28). NG Repair or replace harness or connector. OK If same code is still output after DTC is deleted, check contact condition of each connection. If connector are normal, ECU may be defective. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI-210 DIAGNOSTICS - ANTI-LOCK BRAKE SYSTEM DI5M3-02 DTC 31, 32, 33, 34, 35, 36 Speed Sensor Circuit CIRCUIT DESCRIPTION Rotor The speed sensor detects wheel speed and sends the appropriate signals to the ECU. These signals are used to control the ABS system. The front and rear rotors each have 48 serrations. When the rotors rotate, the magnetic field emitted by the permanent magnet in the speed sensor generates an AC voltage. Since the frequency of this AC voltage changes in direct proportion to the speed of the rotor, the frequency is used by the ECU to detect the speed of each wheel. Speed Sensor S Magnet N Coil To ECU Low Speed High Speed +V BR3583 BR3582 -V F00010 DTC No. DTC Detecting Condition Trouble Area 31, 32, 33, 34 Detection of any of conditions (1) through (3): (1) At vehicle speed of 10 km/h (6 mph) or more, pulses are not input for 5 sec. (2) Momentary interruption of the speed sensor signal occurs at least 7 times in the time between switching the ignition switch ON and switching it OFF. (3) Abnormal fluctuation of speed sensor signals with the vehicle speed 20 km/h (12 mph) or more.
Right front, left front, right rear and left rear speed sensor
Open or short in each speed sensor circuit
Sensor rotor 35 Speed sensor signal is not input for about 1 sec. while the left front and right rear speed sensor signals are being checked with the IG switch ON.
Open in left front or right rear speed sensor circuit 36 Speed sensor signal is not input for about 1 sec. while the right front and left rear speed sensor signals are being checked with the IG switch ON.
Open in right front or left rear speed sensor circuit HINT:



DTC No. 31 is for the right front speed sensor. DTC No. 32 is for the left front speed sensor. DTC No. 33 is for the right rear speed sensor. DTC No. 34 is for the left rear speed sensor. Fail safe function: If trouble occurs in the speed sensor circuit, the ECU cuts off current to the ABS control (solenoid) relay and prohibits ABS control. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI-211 DIAGNOSTICS - ANTI-LOCK BRAKE SYSTEM WIRING DIAGRAM ABS ECU Left Front Speed Sensor 2 W 1 B 2 9 V Bd1 A13 FL+ P Bd2 A13 FL- 22 10 4 BR Right Front Speed Sensor 1 W 2 B 1 A13 FSS 16 B Bd1 A13 FR+ Y Bd2 A13 FR- 3 3 2 W 1 B R Bh1 W W Bh1 W-B 4 5 GR Bh1 2 W Right Rear Speed Sensor Bf1 3 R 1 Left Rear Speed Sensor 1 2 Bf1 B 2 Bg1 Bg1 1 L Y-G 1 Bh1 Bh1 2 L G 4 BQ2 BQ2 R W 3 ID3 ID3 5 6 2 11 BQ2 ID3 1 BQ2 BQ2 L G 2 5 ID3 ID3 4 9 R A12 RL+ W A12 RL- BR-B L G 1 7 A12 RSS 8 A12 RR+ A12 RR- 16 W02194 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI-212 DIAGNOSTICS - ANTI-LOCK BRAKE SYSTEM INSPECTION PROCEDURE 1 Front: Check speed sensor. FL+ FR+ FL- FR- Rear: RL- RL+ RR+ RR- W02210 W02209 W02207 W02208 F00036 Front PREPARATION: Disconnect speed sensor connector. CHECK: Measure resistance between terminals 1 and 2, 3 and 4 of speed sensor connector. OK: Resistance: 0.6 - 2.0 kΩ CHECK: Measure resistance between terminals 1 and 2 of speed sensor connector and body ground. OK: Resistance: 1 MΩ or higher Rear PREPARATION: Disconnect speed sensor connector. CHECK: Measure resistance between terminals 1 and 2 of speed sensor connector. OK: Resistance: 0.5 - 1.6 kΩ CHECK: Measure resistance between terminals 1 and 2 of speed sensor connector and body ground. OK: Resistance: 1 MΩ or higher NG Replace speed sensor. NOTICE: Check the speed sensor signal last (See page DI-189 ). OK 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI-213 DIAGNOSTICS 2 - ANTI-LOCK BRAKE SYSTEM Check for open and short in harness and connector between each speed sensor and ECU (See page IN-27 ). NG Repair or replace harness or connector. OK 3 Check speed sensor and rotor serrations. 1V/Division Normal Signal Waveform GND 2 ms/Division Reference: INSPECTION USING OSCILLOSCOPE PREPARATION: (a) Remove the ABS ECU with connector still connected. (b) Connect the oscilloscope to the terminals FR+, FL+, RR+ or RL+ and GND of the ABS ECU. CHECK: Drive the vehicle at 30 km/h (19 mph), and check the signal waveform. W04200 OK Turn the IG swithch OFF, check and replace ABS ECU. NG 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI-214 DIAGNOSTICS 4 - ANTI-LOCK BRAKE SYSTEM Check sensor rotor and sensor installation. R04759 R04775 OK Front PREPARATION: Remove front axle hub and knuckle spindle (See page SA-8 ). CHECK: Check the sensor rotor serrations. OK: No scratches or missing teeth. CHECK: Check the sensor tip and grease. OK: No scratches or foreign objects on the sensor tip and grease. Rear PREPARATION: Remove the rear brake caliper and disc. CHECK: Check the sensor rotor serrations. OK: No scratches or missing teeth. CHECK: Check the sensor tip. OK: No scratches or foreign objects on the sensor tip. CHECK: Check the speed sensor installation. OK: The installation bolt is tightened properly and there is no clearance between the sensor and steering knuckle or rear axle carrier. NG NG Replace speed sensor or rotor. BR3795 NOTICE: Check the speed sensor signal last (See page DI-189 ). OK Check and replace ABS ECU. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−215 DIAGNOSTICS − ANTI−LOCK BRAKE SYSTEM DI5M4−02 DTC 41 IG Power Source Circuit CIRCUIT DESCRIPTION This is the power source for the ECU, hence the CPU and actuators. DTC No. DTC Detecting Condition Trouble Area Vehicle speed is 3 km/h (1.9 mph) or more and voltage of ECU terminal IG1 remains at more than 17 V or below 9.5 V for more than 10 sec. 41 S Battery S IC regulator S Open or short in power source circuit Fail safe function: If trouble occurs in the power source circuit, the ECU cuts off current to the ABS control (solenoid) relay and prohibits ABS control. WIRING DIAGRAM B EA2 2 AM1 2 6 R/B No. 2 2 1 ABS ECU Ignition Switch B 4 ECU−IG 3 B−W 2 B−Y 1 J6 Junction Connector Deceleration Sensor B B B W BR 2 B−W 12 A13 2 A13 +B GND 3 R/B No. 2 BR 4 2 15 A13 GND BR B−L IE AM1 F6 1 Battery W02195 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−216 DIAGNOSTICS − ANTI−LOCK BRAKE SYSTEM INSPECTION PROCEDURE 1 Check battery positive voltage. OK: Voltage: 10 − 14 V NG Check and repair charging system. OK 2 Check voltage between terminals IG1 and GND of ABS ECU connector. PREPARATION: Remove the ABS ECU with connectors still connected. CHECK: (a) Turn the ignition switch ON. (b) Measure the voltage between terminals IG1 and GND of the ABS ECU connector. OK: Voltage: 10 − 14 V ON (−) (+) IG1 GND GND BE6653 R14207 F00034 OK Check and replace ABS ECU. NG 3 Check continuity between terminals GND of ABS ECU connector and body ground. CHECK: Measure the resistance between terminal GND of the ABS ECU connector and body ground. OK: Resistance: 1 Ω or less LOCK GND GND BE6653 R14208 F00035 NG Repair or replace harness or connector. OK 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−217 DIAGNOSTICS 4 − ANTI−LOCK BRAKE SYSTEM Check ECU−IG fuse. PREPARATION: Remove the ECU−IG fuse from the Fuse block. CHECK: Check the continuity of the ECU−IG fuse. OK: Continuity Fuse Block ECU−IG W02206 NG Check for short in all harness and components connected to ECU−IG fuse (See attached wiring diagram). OK Check for open in harness and connector between ABS ECU and battery (See page IN−28). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−218 DIAGNOSTICS − ANTI−LOCK BRAKE SYSTEM DI5M6−02 DTC 43 Malfunction in Deceleration Sensor CIRCUIT DESCRIPTION DTC No. DTC Detecting Condition Trouble Area 43 Either of the following 1 or 2 is detected: 1. After the battery terminal is connected, input from the deceleration sensor does not change at one cycle (0 km/h → more than 30 km/h → 0 km/h) for 16 times continuously 2. When the brake pedal is not depressed at vehicle speed of 5 km/h or more, forward and backward G (more than 0.4 G) is detected for 30 seconds or more S Deceleration sensor S Wire harness for deceleration sensor system INSPECTION PROCEDURE 1 Check deceleration sensor (See page DI−190). NG Replace deceleration sensor. OK 2 Check for open or short in harness and connector between sensor and ECU (See page IN−28). NG Repair or replace harness and connector. OK Check and replace ABS ECU. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−219 DIAGNOSTICS − ANTI−LOCK BRAKE SYSTEM DI5M8−02 DTC 44 Deceleration Sensor Circuit CIRCUIT DESCRIPTION This sensor detects deceleration on the vehicle. The sensor signal is used in ABS control. If the sensor functions abnormally, the ABS warning light comes on but the ABS still operates. DTC No. DTC Detecting Condition Trouble Area 44 Either of the following 1 or 2 is detected: 1. An open or short is detected in circuit GS1 or GS2 for 1sec. 2. After the ignition is turned ON, the test signal is output by GST During this time, a trouble signal is detected for 0.5 sec. S Deceleration sensor S Open or short in deceleration sensor circuit WIRING DIAGRAM ABS ECU B B−W B−W B B Junction Connector ABS ECU 15 ID2 B−W 12 V A22 4 3 A22 Deceleration Sensor 3 2 A22 1 A22 ECU−IG Y 14 ID3 Y 12 A12 GS1 Y−B 13 3 Y−B GS2 A12 ID3 Y−R 12 10 GST Y−R A12 ID3 12 V A22 6 W−B BF W02196 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−220 DIAGNOSTICS − ANTI−LOCK BRAKE SYSTEM INSPECTION PROCEDURE 1 Check for open and short in harness and connector between Deceleration sensor and ECU (See page IN−28). NG Repair or replace harness or connector. OK 2 Check voltage between terminals GS1, GS2, GST of ABS ECU and body ground. ON (−) (+) GST GS2 GS1 BE6653 W02205 F00037 PREPARATION: (a) Remove the ABS ECU with connectors still connected. (b) Disconnect the deceleration sensor connector. (c) Turn the ignition switch ON. CHECK: Measure the voltage between terminals GS1, GS2, GST of the ECU and Body ground. OK: Voltage: GS1, GS2: 4 − 14 V GST: As shown below ON IG SW OFF 5V GST 1.5 sec. 0.5 sec. 0V F00012 NG Check and replace ABS ECU. OK Check and replace deceleration sensor. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−221 DIAGNOSTICS − ANTI−LOCK BRAKE SYSTEM DI5M9−02 DTC 48 Center Differential Lock Circuit CIRCUIT DESCRIPTION DTC No. 48 DTC Detecting Condition Trouble Area Open or short circuit in center differential lock circuit Center differential is locking S Center differential lock S Center differential lock circuit WIRING DIAGRAM B 4 B−Y 2 1 2 AM1 2 6 EA2 R/B No. 2 1 J1 Junction Connector W 2 2 3 R/B No. 2 Y 3 A ABS ECU Y A C10 5 C11 2 CENTER DIFF. LOCK Indicator Light 4 2 P−B B−L 1 F6 GAUGE B Ignition Switch P−B 19 A13 EXI AM1 P−B CENTER DIFF. LOCK DETECTION Switch Battery W02197 INSPECTION PROCEDURE 1 Check the center differential is free (Transfer is in H position). NG Repair the center differential lock system. OK 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−222 DIAGNOSTICS 2 − ANTI−LOCK BRAKE SYSTEM Is DTC output? Check DTC on page DI−190. NO Normal. YES 3 Check that CENTER DIFF. LOCK indicator light does not go off. NO Go to step 6. YES 4 Check that bulb for CENTER DIFF. LOCK indicator light is not burnt out. YES Replace indicator light. NO 5 Check for open in harness and connector between battery and CENTER DIFF. LOCK indicator light, and CENTER DIFF. LOCK indicator light and ABS ECU (See page IN−28). NG Repair or replace harness or connector. OK 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−223 DIAGNOSTICS 6 − ANTI−LOCK BRAKE SYSTEM Check for short in harness and connector between CENTER DIFF. LOCK indicator light and ABS ECU (See page IN−28). NG Repair or replace harness or connector. OK Check and replace ABS ECU. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−224 DIAGNOSTICS − ANTI−LOCK BRAKE SYSTEM DI5MB−02 DTC 51 ABS Pump Motor Lock CIRCUIT DESCRIPTION DTC No. DTC Detecting Condition 51 Trouble Area Pump motor is not operating normally during initial check S ABS pump motor Fail safe function: If trouble occurs in the ABS pump motor, the ECU cuts off current to the ABS control (solenoid) relay and prohibits ABS control. WIRING DIAGRAM B−W R/B No. 2 1 A6 Motor EA3 1 Relay 2 W−B 2 3 A7 W A13 G−Y A6 Solenoid Relay 1 G−B A7 6 A7 3 2 A6 A7 5 4 B−L B−R 3 A4 A4 4 DLC1 B−L 2 23 A6 2 R/B No. 2 12 V ABS Control Relay 4 G 2 B−W 1 ABS ECU B−W EA3 B−W ABS 2 2 B−W MR 24 R− A13 12 V 11 SR A13 ABS ECU AM1 F6 1 2 W−B 1 A5 A4 A5 W−B Battery ID ABS Actuator 5 L−Y L−W 18 AST A13 A13 MT 6 W02192 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−225 DIAGNOSTICS − ANTI−LOCK BRAKE SYSTEM DI5ME−03 DTC Always ON Malfunction in ECU IG Power Source Circuit CIRCUIT DESCRIPTION This is the power source for the ECU, hence the CPU, and the actuator. DTC No. DTC Detecting Condition Trouble Area Voltage of ECU terminal +B remains at more than 17 V or below 9.5 V Alway ON S Battery S IC regulator S Open or short in power source circuit S ECU Fail safe function: If trouble occurs in the power source circuit, the ECU cuts off current to the ABS control (solenoid) relay and prohibits ABS control. WIRING DIAGRAM B EA2 2 AM1 2 6 R/B No. 2 2 1 ABS ECU Ignition Switch B 4 ECU−IG 2 B−Y 1 3 B−W J6 Junction Connector Deceleration Sensor B B B W BR 2 B−W 12 A13 2 A13 +B GND 3 R/B No. 2 BR 4 2 15 A13 GND BR B−L IE AM1 F6 1 Battery W02195 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−226 DIAGNOSTICS − ANTI−LOCK BRAKE SYSTEM INSPECTION PROCEDURE 1 Is DTC output? Check DTC on page DI−190. YES Repair circuit indicated by code output. YES Check ABS solenoid relay. Check for short in harness and connector between ABS solenoid relay and DLC1 (See page IN−28). YES Check for open or short in harness and connector between ECU−IG fuse and ECU (See page IN−28). NO 2 Is normal code displayed? NO 3 Is ABS warning light go off? NO 4 Check battery positive voltage. PREPARATION: Start the engine. CHECK: Check the battery positive voltage. OK: Voltage: 10 − 16 V NG Check and repair charging system. OK 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−227 DIAGNOSTICS 5 − ANTI−LOCK BRAKE SYSTEM Check ABS warning light. PREPARATION: (a) Turn the ignition switch OFF. (b) Disconnect the connector from the ABS ECU. (c) Turn the ignition switch ON. CHECK: Check the ABS warning light goes off. OK Check and replace ABS ECU. NG Check for short in harness and connector between combination meter and ABS ECU, and combination meter and DLC1 (See page IN−28). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−228 DIAGNOSTICS − ANTI−LOCK BRAKE SYSTEM DI5MG−02 Stop Light Switch Circuit CIRCUIT DESCRIPTION This stop light switch senses whether the brake pedal is depressed or released, and sends the signal to the ECU. WIRING DIAGRAM STOP Stop light Switch 2 G−O 2 ABS ECU 1 G−W G−W 6 A12 STP G−W 2 ID2 G−W High Mounted Stop Light G−W 3 BQ1 G−W Stop Light W−B BG W02198 INSPECTION PROCEDURE 1 Check operation of stop light. CHECK: Check that stop light lights up when brake pedal is depressed and turns off when brake pedal is released. NG Repair stop light circuit (See page BE−24). OK 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−229 DIAGNOSTICS 2 (−) − ANTI−LOCK BRAKE SYSTEM Check voltage between terminal STP of ABS ECU and body ground. (+) PREPARATION: Remove the ABS ECU with connectors still connected. CHECK: Measure the voltage between terminal STP of the ABS ECU and body ground when the brake pedal is depressed. OK: Voltage: 8 − 14 V STP BE6653 R14209 F15325 OK Proceed to next circuit inspection shown on problem symptoms table (See page DI−200). NG 3 Check for open in harness and connector between ABS ECU and stop light switch (See page IN−28). NG Repair or replace harness or connector. OK Check and replace ABS ECU. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−230 DIAGNOSTICS − ANTI−LOCK BRAKE SYSTEM DI5MJ−03 ABS Warning Light Circuit CIRCUIT DESCRIPTION If the ECU detects trouble, it lights the ABS warning light while at the same time prohibiting ABS control. At this time, the ECU records a DTC in memory. After removing the short pin of the DLC1, connect terminals Tc and E1 of the DLC1 to make the ABS warning light blink and output the DTC. WIRING DIAGRAM B−W Battery B−W 2 EA3 GAUGE B−W ABS Control Relay 1 A6 4 A6 1 EA3 Motor Relay 2 B−W A7 W−B A7 6 A7 5 3 Y J1 Junction Connector A 3 A6 ABS ECU Solenoid Relay 1 Short Pin A7 R−L R−L A7 IH1 23 22 20 4 DLC1 A Y C10 5 O B−L A4 4 23 IH1 C10 4 ABS Warning Light O ABS ECU ABS ECU O 13 W O A12 ID ABS Actuator W02199 INSPECTION PROCEDURE Troubleshooting in accordance with the chart below for each trouble symptom. 1 ABS warning light does not light up Go to step 1 ABS warning light remains on Go to step 3 Check ABS warning light. See Combination Meter Troubleshooting on page BE−2. NG Repair bulb or combination meter assembly. OK 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−231 DIAGNOSTICS 2 − ANTI−LOCK BRAKE SYSTEM Check ABS control relay. Continuity Open 2 A7 A6 3 PREPARATION: (a) Turn the ignition switch OFF. (b) Disconnect the connectors from the control relay. CHECK: Check the continuity between each terminal of the ABS control relay. OK: 1 5 6 Continuity R14139 A6 2 A7 1 (−) 3 6 5 Continuity (Reference value 80 Ω) Terminals A7−5 and A7−6 Continuity Terminals A7−2 and A7−5 Open CHECK: (a) Apply battery positive voltage between terminals A7−1 and A6−3. (b) Check the continuity between each terminal of the ABS control relay. OK: Continuity (+) Terminals A7−1 and A6−3 Open Terminals A7−5 and A7−6 Open Terminals A7−2 and A7−5 Continuity R14140 A7 A6 (+) (−) 5 4 CHECK: Connect the ę test lead to terminal A7−4 and the Ĝ test lead to terminal A7−5. Check continuity between the terminals. OK: Continuity If there is no continuity, connect the Ĝ test lead to terminal A7−4 and the ę lead to terminal A7−5. Recheck continuity between terminals. R14144 NG Replace ABS control relay. OK Check for open in harness and connector between DLC1 and ABS control relay and body ground (See page IN−28). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−232 DIAGNOSTICS 3 − ANTI−LOCK BRAKE SYSTEM Is DTC output? Check DTC on page DI−190. YES Repair circuit indicated by code output. NO 4 Does ABS warning light go off if short pin is removed? NO Check for short in harness and connector between warning light and DLC1 and ECU (See page IN−28). YES 5 Check ABS control relay (See step 2). NG Replace ABS control relay. OK Check for short in harness and connector between DLC1 and ABS control relay (See page IN−28). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−233 DIAGNOSTICS − ANTI−LOCK BRAKE SYSTEM DI5ML−02 Tc Terminal Circuit CIRCUIT DESCRIPTION Connecting terminals Tc and E1 of the DLC1 causes the ECU to display the DTC by flashing the ABS warning light. WIRING DIAGRAM ABS ECU 12 V DLC1 BR−B 3 E1 Tc B−Y 11 11 IH1 B−Y 5 A13 Tc EC W02200 INSPECTION PROCEDURE 1 Check voltage between terminals Tc and E1 of DLC1. E1 CHECK: (a) Turn the ignition switch ON. (b) Measure the voltage between terminals Tc and E1 of the DLC1. OK: Voltage: 10 − 14 V Tc DLC1 F00007 OK If ABS warning light does not blink even after Tc and E1 are connected, ECU may be defective. NG 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−234 DIAGNOSTICS 2 − ANTI−LOCK BRAKE SYSTEM Check for open and short in harness and connector between ABS ECU and DLC1, and DLC1 and body ground (See page IN−28). NG Repair or replace harness or connector. OK Check and replace ABS ECU. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−235 DIAGNOSTICS − ANTI−LOCK BRAKE SYSTEM DI5MN−02 Ts Terminal Circuit CIRCUIT DESCRIPTION The sensor check circuit detects abnormalities in the speed sensor signal which cannot be detected with the DTC check. Connecting terminals Ts and E1 of the DLC1 in the engine compartment starts the check. WIRING DIAGRAM ABS ECU 12 V DLC1 BR−B 3 E1 Ts 13 GR−R IH1 16 GR−R 15 Ts A12 EC W01184 INSPECTION PROCEDURE 1 Check voltage between terminals Ts and E1 of DLC1. E1 CHECK: (a) Turn the ignition switch ON. (b) Measure the voltage between terminals Ts and E1 of the DLC1. OK: Voltage: 10 − 14 V Ts DLC1 F00007 OK If ABS warning light does not blink even after Ts and E1 are connected, ECU may be defective. NG 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−236 DIAGNOSTICS 2 − ANTI−LOCK BRAKE SYSTEM Check for open and short in harness and connector between ABS ECU and DLC1, and DLC1 and body ground (See page IN−28). NG Repair or replace harness or connector. OK Check and replace ABS ECU. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−237 DIAGNOSTICS − ANTI−LOCK BRAKE SYSTEM DI5MP−02 Check for Fluid Leakage Check for fluid leakage from actuator or hydraulic lines. W02202 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−238 DIAGNOSTICS − SUPPLEMENTAL RESTRAINT SYSTEM SUPPLEMENTAL RESTRAINT SYSTEM DI5Q0−02 HOW TO PROCEED WITH TROUBLESHOOTING Perform troubleshoot in accordance with the procedure on the following page. Vehicle Brought to Workshop 1 Customer Problem Analysis DI−239 2 Does Not Light Up Warning Light Check DI−240 Remains on DTC Check and Recording 3 Normal Code DI−240 Malfunction Code 4 Malfunction Code Clearance DI−240 5 DTC Check and Recording Normal Code 6 Normal Code Symptom Simulation DI−240 IN−18 Malfunction Code 7 Malfunction Code DTC Chart DI−243 8 Circuit Inspection DI−271 Identification of Problem 9 10 Repair Malfunction Code Clearance DI−240 11 Malfunction Code DTC Check DI−240 Normal Code 12 Confirmation Test END Step 3, 4, 5, 10, 11, 12 : Diagnostic steps permitting the use of the TOYOTA hand−held tester. 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 405 Brought to you by BirfMark DI−239 − DIAGNOSTICS SUPPLEMENTAL RESTRAINT SYSTEM DI5Q1−01 CUSTOMER PROBLEM ANALYSIS CHECK Inspector’s Name Supplemental Restraint System Check Sheet Registration No. Customer’s Name Registration Year / / Frame No. Date Vehicle Brought In / / km Miles Odometer Reading / Date Problem Dist Occurred Weather Fine Temperature Cloudy Rainy Snowy / Other Approx. Starting Vehicle Operation Driving Idling [ Constant speed Other Acceleration Deceleration ] Road Conditions Details Of Problem Vehicle Inspection, Repair History Prior to Occurrence of Malfunction(Including Supplemental Restraint System) Diagnosis System Inspection SRS Warning Light Inspection 1st Time Remains ON Sometimes Light Up Does Not Light Up 2nd Time Remains ON Sometimes Light Up Does Not Light Up 1st Time Normal Code Malfunction Code [ Code. ] 2nd Time Normal Code Malfunction Code [ Code. ] DTC Inspection 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−240 DIAGNOSTICS − SUPPLEMENTAL RESTRAINT SYSTEM PRE−CHECK 1. (a) (b) DI5Q2−02 SRS WARNING LIGHT CHECK Turn the ignition switch to ACC or ON and check that the SRS warning light lights up. Check that the SRS warning light goes out after approx. 6 seconds. HINT: S R13451 S E1 Tc When the ignition switch is at ACC or ON and the SRS warning light remains on or flashes, the airbag sensor assembly has detected a malfunction code. If, after approx. 6 seconds have elapsed, the SRS warning light sometimes lights up or the SRS warning light lights up even when the ignition switch is OFF, a short in the SRS warning light circuit can be considered likely. Proceed to ”SRS warning light system malfunction” on page DI−274, DI−276. 2. (a) DTC CHECK (Using diagnosis check wire) Output the DTC. (1) Turn the ignition switch to ACC or ON position and wait approx. 20 seconds. (2) Using SST, connect terminals Tc and E1 of the DLC1. SST 09843−18020 (b) Read the DTC. Read the 2−digit DTC as indicated by the number of times the SRS warning light blinks. As an example, the blinking patterns, normal, 11 and 31 are as shown on the illustration. S Normal code indication The light will blink 2 times per second. S Malfunction code indication The first blinking output indicates the first digit of a 2−digit DTC. After a 1.5 second pause, the second blinking output will indicate the second digit. R13006 Normal Code 0.25 ON OFF 0.25 AT0716 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−241 DIAGNOSTICS Code 11 and 31 0.5 4.0 2.5 ON OFF 1.5 Code 11 0.5 Repeat Code 31 AB0056 − SUPPLEMENTAL RESTRAINT SYSTEM If there are 2 or more codes, there will be a 2.5 second pause between each codes. After all the codes have been output, there will be a 4.0 second pause and they will all be repeated. HINT: S In the event of a number of trouble codes, indication will start from the smallest numbered code tot he larger. S If it does not output a DTC or outputs a DTC without terminal connection, proceed to the Tc terminal circuit inspection on page DI−279. 3. (a) (b) DTC CHECK (Using TOYOTA hand−held tester) Hook up the TOYOTA hand−held tester to the DLC1. Read the DTCs by following the prompts on the tester screen. HINT: Please refer to the TOYOTA hand−held tester operator’s manual, for further details. R13819 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−242 DIAGNOSTICS 4. (a) (b) (c) − SUPPLEMENTAL RESTRAINT SYSTEM DTC CLEARANCE (Using diagnosis check wire) Connect the 2 service wires to terminals Tc and AB of DLC1. Turn the ignition switch to ACC or ON and wait approx. 6 seconds. Starting with the Tc terminal, apply body ground alternately to terminal Tc and terminal AB twice each in cycles of 1.0 seconds. Confirm that body ground is absolute. Finally, keep applying body ground to terminal Tc. HINT: When alternately grounding terminals Tc and AB, release ground from one terminal and immediately apply it to the other terminal within an interval of 0.2 second. If DTCs do not clear, repeat the above procedure until the codes are cleared. Terminal Time of Body Ground OFF Tc Tc AB 1 second 1 second Body Ground (±0.5 sec.) (±0.5 sec.) ”3” ”1” ”5” OFF AB Body Ground ”2” ”4” Several seconds ON 50 m sec. OFF 50 m sec. H00059 (d) 5. (a) (b) R13819 Several seconds after doing the clearing procedure, the SRS waring light will blink in a 50 m sec. cycle to indicate the codes have been cleared. USING TOYOTA HAND−HELD TESTER Hook up the TOYOTA hand−held tester to the DLC1. Clear the DTC by following the prompts on the tester screen. HINT: Please refer to the TOYOTA hand−held tester operator’s manual for further details. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−243 DIAGNOSTICS − SUPPLEMENTAL RESTRAINT SYSTEM DI5Q3−02 DIAGNOSTIC TROUBLE CODE CHART If a malfunction code is displayed during the DTC check, the circuit listed for that code in the table below (Proceed to the page given for that circuit.). DTC No. (See Page) Normal (DI−271) Detection Item − OFF S Source voltage drop S Battery S Airbag sensor assembly ON S Short in squib circuit (to ground) S Steering wheel pad (D squib) S Front passenger airbag assembly (P squib ) S Spiral cable S Airbag sensor assembly S Wire harness ON S Steering wheel pad (D squib) S Front passenger airbag assembly (P squib) S Spiral cable S Airbag sensor assembly S Wire harness ON S Steering wheel pad (D squib) S Spiral cable S Airbag sensor assembly S Wire harness ON S Short in squib circuit (to B+) 12 (DI−254) S Open in D squib circuit 14 (DI−260) 54 (DI−267) SRS Warning Light S System normal 11 (DI−247) 31 (DI−265) Trouble Area S Airbag sensor assembly malfunction S Airbag sensor assembly S Open in P squib circuit S Front passenger airbag assembly (P squib) S Airbag sensor assembly S Wire harness ON ON HINT: S S S When the SRS warning light remains lit up and the DTC is the normal code, this means a source drop voltage. This malfunction is not stored in memory by the airbag sensor assembly and if the power source voltage returns to normal, the SRS warning light will automatically go out. When 2 or more codes are indicated, the codes will be displayed in numeral order starting from the lowest numbered code. If a code not listed on the chart is displayed, the airbag sensor assembly is faulty. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−244 DIAGNOSTICS − SUPPLEMENTAL RESTRAINT SYSTEM DI5Q4−02 PARTS LOCATION Steering Wheel Pad (With Airbag) Front Passenger Airbag Assembly Spiral Cable Airbag Sensor Assembly R13515 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−245 − DIAGNOSTICS SUPPLEMENTAL RESTRAINT SYSTEM DI5Q5−02 TERMINALS OF ECM 2 1 B A 4 10 3 9 8 7 6 5 W02056 No. Symbol Terminal Name A − Electrical Connection Check Mechanism B − Electrical Connection Check Mechanism 1 P− Squib Ĝ (Passenger) 2 P+ Squib ę (Passenger) 3 D− Squib Ĝ (Driver) 4 D+ Squib ę (Driver) 5 E1 Ground 6 E2 Ground 7 Tc Diagnosis 8 LA SRS Warning Light 9 IG2 Power Source (IGN Fuse) 10 ACC Power Source (CIG Fuse) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−246 DIAGNOSTICS − SUPPLEMENTAL RESTRAINT SYSTEM DI5Q6−01 PROBLEM SYMPTOMS TABLE Proceed with troubleshooting of each circuit in the table below. Symptom Suspect Area See page S With the ignition switch at ACC or ON, the SRS warning light sometimes lights up after approx. 6 seconds have elapsed. S SRS warning light lights up even when ignition switch is in the LOCK position. S SRS warning light system malfunction (Always lit up when ignition switch is in LOCK position.) DI−274 S With the ignition switch at ACC or ON, the SRS warning lights does not light up. S SRS warning light system malfunction (Does not light up when ignition switch is turned to ACC or ON.) DI−276 S DTC not displayed. S SRS warning light is always lit up with a DTC check procedure. S DTC displayed without Tc and E1 terminal connection. S Tc terminal circuit DI−279 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−247 DIAGNOSTICS − SUPPLEMENTAL RESTRAINT SYSTEM DI5Q7−03 CIRCUIT INSPECTION DTC 11 Short in Squib Circuit (to Ground) CIRCUIT DESCRIPTION The squib circuit consists of the airbag sensor assembly, spiral cable, steering wheel pad and front passenger airbag assembly. If causes the SRS to deploy when the SRS deployment conditions are satisfied. For details of the function of each component, see FUNCTION OF COMPONENTS on page RS−2. DTC 11 is recorded when ground short is detected in the squib circuit. DTC No. 11 DTC Detection Condition Trouble Area S Steering wheel pad (D squib) S Front passenger airbag assembly (P squib) S Spiral cable S Airbag sensor assembly S Wire harness S Short circuit in squib wire harness (to ground) S Squib malfunction S Spiral cable malfunction S Airbag sensor assembly malfunction WIRING DIAGRAM Airbag Sensor Assembly W−R 2 B−R 1 P− W 4 D+ B 3 1 P Squib 2 1 D Squib 2 P+ D− Spiral Cable R16017 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−248 DIAGNOSTICS − SUPPLEMENTAL RESTRAINT SYSTEM INSPECTION PROCEDURE 1 Preparation. (See step 1 on page DI−271) 2 Check D squib circuit. Airbag Sensor Assembly P Squib D Squib Spiral Cable D− R05901 R14290 CHECK: For the connector (on the spiral cable side) between the spiral cable and steering wheel pad, measure the resistance between D+, D− and body ground. OK: Resistance: 1 MΩ or Higher D+ H00004 NG Go to step 7. OK 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−249 DIAGNOSTICS 3 SUPPLEMENTAL RESTRAINT SYSTEM Check P squib circuit. P− P Squib D Squib − P+ Airbag Sensor Assembly CHECK: For the connector (on the airbag sensor assembly side) between the airbag sensor assembly and front passenger airbag assembly, measure the resistance between P+, P− and body ground. OK: Resistance: 1 MΩ or Higher Spiral Cable R14291 R05896 H00005 NG Repair or replace harness or connector between the airbag sensor assembly and front passenger airbag assembly. OK 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−250 DIAGNOSTICS 4 − SUPPLEMENTAL RESTRAINT SYSTEM Check airbag sensor assembly. P+ P− P Squib Airbag Sensor Assembly Spiral Cable D Squib D− D+ ACC ON or Code 11 DLC1 E1 Tc AB0069 W01933AB0069 AB0118 AB0118 R13006 W02042 H00006 PREPARATION: (a) Connect connector to airbag sensor assembly. (b) Using service wire, connect D+ and D− on spiral cable side of connector between spiral cable and steering wheel pad. (c) Using a service wire, connect P+ and P− on airbag sensor assembly side of connector between airbag sensor assembly and front passenger airbag assembly. (d) Connect negative (−) terminal cable to battery, and wait at least 2 seconds. CHECK: (a) Turn ignition switch to ACC or ON and wait at least 20 seconds. (b) Clear malfunction code stored in memory. (See page DI−240) (c) Turn ignition switch to LOCK, and wait at least 20 seconds. (d) Turn ignition switch to ACC or ON, and wait at least 20 seconds. (e) Using SST, connect terminals Tc and E1 of DLC1. SST 09843−18020 (f) Check DTC OK: DTC 11 is not output. HINT: Codes other than code 11 may be output at this time, but they are not relevant to this check. NG Replace airbag sensor assembly. OK 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−251 DIAGNOSTICS 5 − SUPPLEMENTAL RESTRAINT SYSTEM Check D squib. Airbag Sensor Assembly P Squib D Squib Spiral Cable ACC ON or Code 11 DLC1 E1 Tc R05896 AB0118 AB0119 R13006 W02042 H00007 PREPARATION: (a) Turn ignition switch to LOCK. (b) Disconnect negative (−) terminal cable from the battery, and wait at least 90 seconds. (c) Connect steering wheel pad connector. (d) Connect negative (−) terminal cable to battery, and wait at least 2 seconds. CHECK: (a) Turn ignition switch to ACC or ON, and wait at least 20 seconds. (b) Clear malfunction code stored in memory. (See page DI−240) (c) Turn ignition switch to LOCK, and wait at least 20 seconds. (d) Turn ignition switch to ACC or ON, and wait at least 20 seconds. (e) Using SST, connect terminals Tc and E1 of DLC1. SST 09843−18020 (f) Check DTC. OK: DTC 11 is not output. HINT: Codes other than code 11 may be output at this time, but they are not relevant to this check. NG Replace steering wheel pad. OK 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−252 DIAGNOSTICS 6 − SUPPLEMENTAL RESTRAINT SYSTEM Check P squib. Airbag Sensor Assembly P Squib Spiral Cable D Squib ACC ON or Code 11 DLC1 E1 Tc R05897 AB0118 AB0119 R13006 W02042 H00008 PREPARATION: (a) Turn ignition switch to LOCK. (b) Disconnect negative (−) terminal cable from the battery, and wait at least 90 seconds. (c) Connect front passenger airbag assembly connector. (d) Connect negative (−) terminal cable to battery, and wait at least 2 seconds. CHECK: (a) Turn ignition switch to ACC or ON, and wait at least 20 seconds. (b) Clear malfunction code stored in memory. (See page DI−240) (c) Turn ignition switch to LOCK, and wait at least 20 seconds. (d) Turn ignition switch to ACC or ON, and wait at least 20 seconds. (e) Using SST, connect terminals Tc and E1 of DLC1. SST 09843−18020 (f) Check DTC. OK: DTC 11 is not output. HINT: Codes other than code 11 may be output at this time, but they are not relevant to this check. NG Replace front passenger airbag assembly. OK From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−253 DIAGNOSTICS 7 − SUPPLEMENTAL RESTRAINT SYSTEM Check spiral cable. P Squib D Squib Airbag Sensor Assembly Spiral Cable D+ R05899 R14301 H00009 PREPARATION: Disconnect connector between airbag sensor assembly and spiral cable. CHECK: Measure resistance between D+ on spiral cable side of connector between spiral cable and steering wheel pad and body ground. OK: Resistance: 1 MΩ or Higher NG Repair or replace spiral cable. OK Repair or replace harness or connector between airbag sensor assembly and spiral cable. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−254 DIAGNOSTICS − SUPPLEMENTAL RESTRAINT SYSTEM DI5Q8−03 DTC 12 Short in Squib Circuit (to B+) CIRCUIT DESCRIPTION The squib circuit consists of the airbag sensor assembly, spiral cable, steering wheel pad and front passenger airbag assembly. It causes the SRS to deploy when the SRS deployment conditions are satisfied. For details of the function of each component, see page FUNCTION OF COMPONENTS on page RS−2. DTC 12 is recorded when a B+ short is detected in the squib circuit. DTC No. DTC Detection Condition Trouble Area S Steering wheel pad (D squib) S Front passenger airbag assembly (P squib) S Spiral cable S Airbag sensor assembly S Wire harness S Short circuit in squib wire harness (to B+) S Squib malfunction S Spiral cable malfunction S Airbag sensor assembly malfunction 12 WIRING DIAGRAM Refer to page DI−247 for the WIRING DIAGRAM. INSPECTION PROCEDURE 1 Preparation. (See step 1 on page DI−271) 2 Check D squib circuit. ON Airbag Sensor Assembly P Squib D Squib Spiral Cable D− (−) CHECK: For the connector (on the spiral cable side) between the spiral cable and steering wheel pad, measure the voltage between D+, D− and body ground. OK: Voltage: 0 V D+ (+) AB0119 W01931 R14300 H00010 NG Go to step 7. OK 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−255 DIAGNOSTICS 3 − SUPPLEMENTAL RESTRAINT SYSTEM Check P squib circuit. ON P− (−) (+) P Squib D Squib P+ CHECK: For the connector (on the airbag sensor assembly side) between airbag sensor assembly and front passenger airbag assembly, measure the voltage between P+, P− and body ground. OK: Voltage: 0 V Airbag Sensor Assembly Spiral Cable AB0119 R05898 R14300 H00011 NG Repair or replace harness or connector between the airbag sensor assembly and front passenger airbag assembly. OK 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−256 DIAGNOSTICS 4 − SUPPLEMENTAL RESTRAINT SYSTEM Check airbag sensor assembly. P+ P− P Squib Airbag Sensor Assembly Spiral Cable D Squib D+ D− ACC ON or Code 12 DLC1 E1 Tc AB0069 AB0069 W01933 AB0118 AB0119 R13006 W02043 H00012 PREPARATION: (a) Connect connector to airbag sensor assembly. (b) Using a service wire, connect D+ and D− on spiral cable side of connector between spiral cable and steering wheel pad. (c) Using a service wire, connect P+ and P− on airbag sensor assembly side of connector between airbag sensor assembly and front passenger airbag assembly. (d) Connect negative (−) terminal cable to battery, and wait at least 2 seconds. CHECK: (a) Turn ignition switch to ACC or ON, and wait at least 20 seconds. (b) Clear malfunction code stored in memory. (See page DI−240) (c) Turn ignition switch to LOCK, and wait at least 20 seconds. (d) Turn ignition switch to ACC or ON, and wait at least 20 seconds. (e) Using SST, connect terminals Tc and E1 of DLC1. SST 09843−18020 (f) Check DTC. OK: DTC 12 is not output. HINT: Codes other than code 12 may be output at this time, but they are not relevant to this check. NG Replace airbag sensor assembly. OK 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−257 DIAGNOSTICS 5 − SUPPLEMENTAL RESTRAINT SYSTEM Check D squib. Airbag Sensor Assembly P Squib D Squib Spiral Cable ACC ON or Code 12 DLC1 E1 Tc R05896 AB0118 AB0019 R13006 W02043 H00013 PREPARATION: (a) Turn ignition switch to LOCK. (b) Disconnect negative (−) terminal cable from the battery, and wait at least 90 seconds. (c) Connect steering wheel pad connector. (d) Connect negative (−) terminal cable to battery, and wait at least 2 seconds. CHECK: (a) Turn ignition switch to ACC or ON, and wait at least 20 seconds. (b) Clear malfunction code stored in memory. (See page DI−240) (c) Turn ignition switch to LOCK, and wait at least 20 seconds. (d) Turn ignition switch to ACC or ON, and wait at least 20 seconds. (e) Using SST, connect terminals Tc and E1 of DLC1. SST 09843−18020 (f) Check DTC. OK: DTC 12 is not output. HINT: Codes other than code 12 may be output at this time, but they are not relevant to this check. NG Replace steering wheel pad. OK 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−258 DIAGNOSTICS 6 − SUPPLEMENTAL RESTRAINT SYSTEM Check P squib. Airbag Sensor Assembly P Squib Spiral Cable D Squib ACC ON or Code 12 DLC1 E1 Tc R05897 AB0118 AB0119 R13006 W02043 H00014 PREPARATION: (a) Turn ignition switch to LOCK. (b) Disconnect negative (−) terminal cable from the battery, and wait at least 90 seconds. (c) Connect front passenger airbag assembly connector. (d) Connect negative (−) terminal cable to battery, and wait at least 2 seconds. CHECK: (a) Turn ignition switch to ACC or ON, and wait at least 20 seconds. (b) Clear malfunction code stored in memory. (See page DI−240) (c) Turn ignition switch to LOCK, and wait at least 20 seconds. (d) Turn ignition switch to ACC or ON, and wait at least 20 seconds. (e) Using SST, connect terminals Tc and E1 of DLC1. SST 09843−18020 (f) Check DTC. OK: DTC 12 is not output. HINT: Codes other than code 12 may be output at this time, but they are not relevant to this check. NG Replace front passenger airbag assembly. OK From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−259 DIAGNOSTICS 7 − SUPPLEMENTAL RESTRAINT SYSTEM Check spiral cable. Airbag Sensor Assembly P Squib D Squib Spiral Cable D+ (−) ON (+) R05899 AB0119 R14288 H00015 PREPARATION: (a) Turn ignition switch to LOCK. (b) Disconnect connector between airbag sensor assembly and spiral cable. (c) Turn ignition switch ON. CHECK: Measure voltage at D+ on spiral cable side of connector between spiral cable and steering wheel pad and body ground. OK: Voltage: 0 V NG Repair or replace spiral cable. OK Repair or replace harness or connector between airbag sensor assembly and spiral cable. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−260 DIAGNOSTICS − SUPPLEMENTAL RESTRAINT SYSTEM DI5Q9−03 DTC 14 Open in D Squib Circuit CIRCUIT DESCRIPTION The D squib circuit consists of the airbag sensor assembly, spiral cable and the steering wheel pad. It causes the airbag to deploy when the airbag deployment conditions are satisfied. For details of the function of each component, see FUNCTION OF COMPONENTS on page RS−2. DTC 14 is recorded when an open is detected in the squib circuit. DTC No. DTC Detection Condition D+ 14 Trouble Area D− S Open circuit in wire harness or wire harness of squib S D squib malfunction S Spiral cable malfunction S Center airbag sensor assembly malfunction S Steering wheel pad (D squib) S Spiral cable S Airbag sensor assembly S Wire harness WIRING DIAGRAM Airbag Sensor Assembly W 4 D+ B 3 D− 1 D Squib 2 Spiral Cable R15194 INSPECTION PROCEDURE 1 Preparation. (See step 1 on page DI−271) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−261 DIAGNOSTICS 2 − SUPPLEMENTAL RESTRAINT SYSTEM Check D squib circuit. Airbag Sensor Assembly P Squib D Squib D− Spiral Cable D+ D+ W02055 R14286 R12688 PREPARATION: Using service wire, connect D+ and D− on airbag sensor assembly connector. CHECK: For the connector (on the spiral cable side) between the spiral cable and steering wheel pad, measure the resistance between D+ and D−. OK: Resistance: Below 1 Ω D− H00016 NG Go to step 5. OK 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−262 DIAGNOSTICS 3 − SUPPLEMENTAL RESTRAINT SYSTEM Check airbag sensor assembly. P Squib Airbag Sensor Assembly Spiral Cable D Squib ON ACC D− D+ DLC1 E1 or Code 14 Tc R05895 AB0069 AB0118 AB0119 R13006 W02044 H00017 PREPARATION: (a) Connect connector to airbag sensor assembly. (b) Using a service wire, connect D+ and D− on spiral cable side of connector between spiral cable and steering wheel pad. (c) Connect negative (−) terminal cable to battery, and wait at least 2 seconds. CHECK: (a) Turn ignition switch to ACC or ON and wait at least 20 seconds. (b) Clear malfunction code stored in memory. (See page DI−240) (c) Turn ignition switch to LOCK, and wait at least 20 seconds. (d) Turn ignition switch to ACC or ON, and wait at least 20 seconds. (e) Using SST, connect terminals Tc and E1 of DLC1. SST 09843−18020 (f) Check DTC. OK: DTC 14 is not output. HINT: Codes other than code 14 may be output at this time, but they are not relevant to this check. NG Replace airbag sensor assembly. OK 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−263 DIAGNOSTICS 4 − SUPPLEMENTAL RESTRAINT SYSTEM Check D squib. Airbag Sensor Assembly P Squib D Squib Spiral Cable ACC ON or Code 14 DLC1 E1 Tc R05896 AB0118 AB0119 R13006 W02044 H00018 PREPARATION: (a) Turn ignition switch to LOCK. (b) Disconnect negative (−) terminal cable from the battery, and wait at least 90 seconds. (c) Connect steering wheel pad (squib) connector. (d) Connect negative (−) terminal cable to battery, and wait at least 2 seconds. CHECK: (a) Turn ignition switch to ACC or ON, and wait at least 20 seconds. (b) Clear malfunction code stored in memory. (See page DI−240) (c) Turn ignition switch to LOCK, and wait at least 20 seconds. (d) Turn ignition switch to ACC or ON, and wait at least 20 seconds. (e) Using SST, connect terminals Tc and E1 of DLC1. SST 09843−18020 (f) Check DTC. OK: DTC 14 is not output. HINT: Codes other than code 14 may be output at this time, but they are not relevant to this check. NG Replace steering wheel pad. OK From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−264 DIAGNOSTICS 5 − SUPPLEMENTAL RESTRAINT SYSTEM Check spiral cable. Airbag Sensor Assembly P Squib Spiral Cable D Squib D+ D− R05899 R14286 H00019 PREPARATION: Disconnect connector between airbag sensor assembly and spiral cable. CHECK: For the connector (on the spiral cable side) between the spiral cable and steering wheel pad, measure the resistance D+ and D−. OK: Resistance: Below 1 Ω NG Repair or replace spiral cable. OK 6 Check harness between airbag sensor assembly and spiral cable. Airbag Sensor Assembly P Squib D Squib D− Spiral Cable D+ D+ D− PREPARATION: Using service wire, connect D+ and D− on airbag sensor assembly connector. CHECK: For the connector (on the airbag sensor assembly side) between the airbag sensor assembly and spiral cable, measure the resistance between D+ and D−. OK: Resistance: Below 1 Ω NG W01932 R14286 R12688 H00020 Repair or replace harness or connector between airbag sensor assembly and spiral cable. OK From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−265 DIAGNOSTICS − SUPPLEMENTAL RESTRAINT SYSTEM DI5QA−03 DTC 31 Airbag Sensor Assembly Malfunction CIRCUIT DESCRIPTION The airbag sensor assembly consists of a airbag sensor, safing sensor, drive circuit, diagnosis circuit and ignition control, etc. It receives signals from the airbag sensors, judges whether or not the SRS must be activated, and diagnosis system malfunction. DTC 31 is recorded when occurrence of a malfunction in the airbag sensor assembly is detected. DTC No. 31 DTC Detection Condition Trouble Area S Airbag sensor assembly malfunction S Airbag sensor assembly INSPECTION PROCEDURE HINT: When a malfunction code other than code 31 is displayed at the same time, first repair the malfunction indicated by the malfunction code other than code 31. 1 Preparation (See step 1 on page DI−271). 2 Check voltage at IG2 and ACC of airbag sensor assembly. ON Airbag Sensor Assembly ACC (−) IG2 (+) AB0119 R14285 H00021 PREPARATION: Turn ignition switch ON. CHECK: Measure voltage between terminals IG2 and ACC of airbag sensor assembly and body ground. OK: Voltage: Below 16 V NG Check battery and charging system (See page CH−2). OK 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−266 DIAGNOSTICS 3 − SUPPLEMENTAL RESTRAINT SYSTEM Is DTC 31 output again? ACC PREPARATION: Clear malfunction code. CHECK: (a) Turn ignition switch to LOCK, and wait at least 20 seconds. (b) Turn ignition switch to ACC or ON, and wait at least 20 seconds. (c) Repeat operation in step (a) and (b) at least 5 times. (d) Using SST, connect terminals Tc and E1 of DLC 1. SST 09843−18020 (e) Check the DTC. ON or DLC1 E1 Code 31 Tc AB0118 AB0119 R13006 FI1394 H00022 NO Using simulation method, reproduce malfunction symptoms (See page IN−18). YES Replace airbag sensor assembly. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−267 DIAGNOSTICS − SUPPLEMENTAL RESTRAINT SYSTEM DI5QB−03 DTC 54 Open in P Squib Circuit CIRCUIT DESCRIPTION The P squib circuit consists of the airbag sensor assembly and front passenger airbag assembly. It causes the airbag to deploy when the airbag deployment conditions are satisfied. For details of the function of each component, see FUNCTION OF COMPONENTS on page RS−2. DTC 54 is recorded when an open is detected in the P squib circuit. DTC No. DTC Detection Condition P+ 54 Trouble Area P− S Open circuit in wire harness or wire harness of squib S Squib malfunction S Airbag sensor assembly malfunction S Front passenger airbag assembly (P squib) S Airbag sensor assembly S Wire harness WIRING DIAGRAM Airbag Sensor Assembly W−R 2 B−R 1 1 P+ P Squib 2 P− R15195 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−268 DIAGNOSTICS − SUPPLEMENTAL RESTRAINT SYSTEM INSPECTION PROCEDURE 1 Preparation. (See step 1 on page DI−271) 2 Check P squib circuit. P+ P− P+ P− P Squib D Squib R14287 R12689 W01936 Spiral Cable PREPARATION: Using service wire, connect P+ and P− on airbag sensor assembly connector. CHECK: For the connector (on the airbag sensor assembly side) between the airbag sensor assembly and front passenger airbag assembly measure the resistance between P+ and P−. OK: Resistance: Below 1 Ω Airbag Sensor Assembly H00023 NG Repair or replace harness or connector between airbag sensor assembly and front passenger airbag assembly. OK 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−269 DIAGNOSTICS 3 − SUPPLEMENTAL RESTRAINT SYSTEM Check airbag sensor assembly. P+ P− Airbag Sensor Assembly P Squib Spiral Cable D Squib ACC ON or DLC1 E1 Code 54 Tc AB0069 W01934 AB0118 AB0119 R13006 W02045 H00024 PREPARATION: (a) Connect connector to airbag sensor assembly. (b) Using service wire, connect P+ and P− on airbag sensor assembly side of connector between airbag sensor assembly and front passenger airbag assembly. (c) Connect negative (−) terminal cable to battery, and wait at least 2 seconds. CHECK: (a) Turn ignition switch to ACC or ON, and wait at least 20 seconds. (b) Clear malfunction code stored in memory. (See page DI−240) (c) Turn ignition switch to LOCK, and wait at least 20 seconds. (d) Turn ignition switch to ACC or ON, and wait at least 20 seconds. (e) Using SST, connect terminals Tc and E1 of DLC1. SST 09843−18020 (f) Check DTC. OK: DTC 54 is not output. HINT: Codes other than code 54 may be output at this time, but they are not relevant to this check. NG Replace airbag sensor assembly. OK 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−270 DIAGNOSTICS 4 − SUPPLEMENTAL RESTRAINT SYSTEM Check P squib. Airbag Sensor Assembly P Squib Spiral Cable D Squib ACC ON or DLC1 E1 Code 54 Tc R05909 AB0118 AB0119 R13006 W02045 H00025 PREPARATION: (a) Turn ignition switch to LOCK. (b) Disconnect negative (−) terminal cable from the battery, and wait at least 90 seconds. (c) Connect front passenger airbag assembly connector. (d) Connect negative (−) terminal cable to battery, and wait at least 2 seconds. CHECK: (a) Turn ignition switch to ACC or ON and wait at least 20 seconds. (b) Clear malfunction code stored in memory. (See page DI−240) (c) Turn ignition switch to LOCK, and wait at least 20 seconds. (d) Turn ignition switch to ACC or ON, and wait at least 20 seconds. (e) Using SST, connect terminals Tc and E1 of DLC1. SST 09843−18020 (f) Check DTC. OK: DTC 54 is not output. HINT: Codes other than code 54 may be output at this time, but they are not relevant to this check. NG Replace front passenger airbag assembly. OK From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−271 DIAGNOSTICS − SUPPLEMENTAL RESTRAINT SYSTEM DI5QC−03 DTC Normal Source Voltage Drop CIRCUIT DESCRIPTION The SRS is equipped with a voltage−increase circuit (DC−DC converter) in the airbag sensor assembly in case the source voltage drops. When the battery voltage drops, the voltage−increase circuit (DC−DC converter) functions to increase the voltage of the SRS to normal voltage. The diagnosis system malfunction display for this circuit is different to other circuits−when the SRS warning light remains lit up and the DTC is a normal code, source voltage drop is indicated. Malfunction in this circuit is not recorded in the airbag sensor assembly, and the source voltage returns to normal, the SRS warning light automatically goes off. DTC No. DTC Detection Condition Normal Trouble Area S Battery S Airbag sensor assembly Source voltage dorp WIRING DIAGRAM 6 B EA2 50A AM1 2 3 EA2 W−R 11 4 A GR S5 3 L−R 1 CIG 2 GR A 6 B−R 1 IGN 2 Ignition Switch J3 Junction Connector B−L F/B 4 GR 10 S4 ACC 3 3 B−W 9 S4 IG2 S5 Short Connector W R/B No.2 2 B 4 W−R 2 FL BLOCK AM2 AM1 B−L 2 Airbag Sensor Assembly Battery R13678 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−272 DIAGNOSTICS − SUPPLEMENTAL RESTRAINT SYSTEM INSPECTION PROCEDURE 1 Preparation. LOCK Airbag Sensor Assembly P Squib D Squib Spiral Cable AB0117 R05894 2 H00001 PREPARATION: (a) Disconnect negative (−) terminal cable from the battery, and wait at least 90 seconds. (b) Remove steering wheel pad (See page SR−11). (c) Disconnect connector of front passenger airbag assembly (See page RS−22). (d) Disconnect connector of airbag sensor assembly (See page RS−33). CAUTION: Store the steering wheel pad with the front surface facing upward. Check source voltage. ON Airbag Sensor Assembly ACC (−) IG2 (+) AB0119 R14285 PREPARATION: (a) Connect negative (−) terminal cable to battery. (b) Turn ignition switch ON. CHECK: Measure voltage at IG2 or ACC on sensor and operate electric system. (defogger, wiper, headlight, heater blower, etc.) OK: Voltage: 10 − 14 V H00021 NG Check the harness between battery and airbag sensor assembly, and check the battery and charging system. OK 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−273 DIAGNOSTICS 3 − SUPPLEMENTAL RESTRAINT SYSTEM Does SRS warning light turn off? ON H00003 PREPARATION: (a) Turn ignition switch to LOCK. (b) Connect steering wheel pad connector. (c) Connect front passenger airbag assembly connector. (d) Connect airbag sensor assembly connector. (e) Turn ignition switch ON. CHECK: Operate electric system (defogger, wiper, headlight, heater blower, etc.) and check that SRS warning light goes off. NO Check DTC, if a DTC is output, perform troubleshooting according to DTC, if a normal code is output, replace airbag sensor assembly. YES From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−274 DIAGNOSTICS − SUPPLEMENTAL RESTRAINT SYSTEM DI5QD−03 SRS Warning Light System Malfunction (Always lit up, when ignition switch is in LOCK position.) CIRCUIT DESCRIPTION The SRS warning light is located on the combination meter. When the SRS is normal, the SRS warning light lights up for approx. 6 seconds after the ignition switch is turned from LOCK position to ACC or ON position, and then turns off automatically. If there is a malfunction in the SRS, the SRS warning light lights up to inform the driver of the abnormality. When terminals Tc and E1 of the DLC1 are connected, the DTC is displayed by the blinking of the SRS warning light. WIRING DIAGRAM Airbag Sensor Assembly W 1 SRS Warning Light 3 2 B−R 2 1 S7 W−L ECU−B F/B 1 S6 W−L 8 LA Short Connector FL BLOCK 2 S7 8 B−Y 5 B−L 7 Tc IH1 11 B−Y Cruise Control ECU W−L IH1 12 2 S6 Short Connector B−Y W GENERATOR (ALTERNATOR) MAIN W−L W 3 EA3 11 Battery DLC1 R13679 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−275 DIAGNOSTICS − SUPPLEMENTAL RESTRAINT SYSTEM INSPECTION PROCEDURE 1 Preparation. LOCK Airbag Sensor Assembly P squib D squib Spiral Cable H00094 2 LOCK PREPARATION: (a) Disconnect negative (−) terminal cable from the battery, and wait at least 90 seconds. (b) Remove steering wheel pad. (See SR section) (c) Disconnect connector of front passenger airbag assembly. (See page RS−22) CAUTION: Store the steering wheel pad with the front surface facing upward. Does SRS warning light turn off? Airbag Sensor Assembly AB0117 N12639 PREPARATION: (a) Turn ignition switch to LOCK. (b) Disconnect negative (−) terminal cable from the battery, and wait at least 90 seconds. (c) Disconnect airbag sensor assembly connector. (d) Connect negative (−) terminal cable to battery. CHECK: Check operation of SRS warning light. H00026 NO Check SRS warning light circuit or terminal AB circuit of DLC1. YES Replace airbag sensor assembly. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−276 DIAGNOSTICS − SUPPLEMENTAL RESTRAINT SYSTEM DI5QE−03 SRS Warning Light System Malfunction (Does not light up, when ignition switch is turned to ACC or ON.) CIRCUIT DESCRIPTION The SRS warning light is located on the combination meter. When the SRS is normal, the SRS warning light lights up for approx. 6 seconds after the ignition switch is turned from LOCK position to ACC or ON position, and then turns off automatically. If there is a malfunction in the SRS, the SRS warning light lights up to inform the driver of the abnormality. When terminals Tc and E1 of the DLC1 are connected, the DTC is displayed by the blinking of the SRS warning light. WIRING DIAGRAM Refer to page DI−274 for the WIRING DIAGRAM. INSPECTION PROCEDURE 1 Check ECU−B Fuse. Fuse N14677 PREPARATION: Remove ECU−B fuse. CHECK: Check continuity of ECU−B fuse. OK: Continuity HINT: S Fuse may be burnt out even if it appears to be OK during visual inspection. S If fuse is OK, install it. NG Go to step 5. OK 2 Preparation. (See step 1 on page DI−271) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−277 DIAGNOSTICS 3 − SUPPLEMENTAL RESTRAINT SYSTEM Check SRS warning light circuit. ON Airbag Sensor Assembly LA (−) (+) AB0119 R14302 PREPARATION: (a) Connect negative (−) terminal cable to battery. (b) Turn ignition switch to ACC or ON. CHECK: Measure voltage LA terminal of harness side connector of airbag sensor assembly. OK: Voltage: 10 − 14 V H00027 NG Check SRS warning light bulb/repair SRS warning light circuit. OK 4 Does SRS warning light come on? P Squib Airbag Sensor Assembly Spiral Cable D Squib ON H00051 PREPARATION: (a) Disconnect negative (−) terminal cable from the battery. (b) Connect airbag sensor assembly connector. (c) Connect negative (−) terminal cable to battery, and wait at least 2 seconds. (d) Turn ignition switch to ACC or ON. CHECK: Check operation of SRS warning light. NO Check terminal LA of airbag sensor assembly. If normal, replace airbag sensor assembly. YES From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−278 DIAGNOSTICS 5 − SUPPLEMENTAL RESTRAINT SYSTEM Is new ECU−B fuse burnt out again? NO Using simulation method, reproduce malfunction symptoms (See page IN−18). YES Check harness between ECU−B fuse and SRS warning light. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−279 DIAGNOSTICS − SUPPLEMENTAL RESTRAINT SYSTEM DI5QF−03 Tc Terminal Circuit CIRCUIT DESCRIPTION By connecting terminals Tc and E1 of the DLC1 the airbag sensor assembly is set in the DTC output mode. The DTCs are displayed by the blinking of the SRS warning light. WIRING DIAGRAM Airbag Sensor Assembly Tc 7 B−L 2 2 S6 S7 B−Y 11 IH1 B−Y 11 Tc E1 3 BR−B Short Connector DLC1 EC R13680 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−280 DIAGNOSTICS − SUPPLEMENTAL RESTRAINT SYSTEM INSPECTION PROCEDURE If the DTC is not displayed, perform the following troubleshooting. 1 Does SRS warning light light up for approx. 6 seconds? LOCK ON ACC or AB0117 AB0118 AB0119 PREPARATION: Check operation of SRS warning light after ignition switch is turned from LOCK position to ACC or ON position. H00258 NO Check SRS warning light system. (See page DI−240) YES 2 Check voltage between terminals Tc and E1 of DLC1. ACC ON or E1 DLC1 (−) Tc PREPARATION: Turn ignition switch to ACC or ON. CHECK: Measure voltage between terminals Tc and E1 of DLC1. OK: Voltage: 10 − 14 V (+) AB0118 AB0119 R14305 H00030 OK Go to step 4. NG 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−281 DIAGNOSTICS 3 − SUPPLEMENTAL RESTRAINT SYSTEM Check voltage between terminals Tc of DLC1 and body ground ACC CHECK: Measure voltage between terminals Tc of DLC1 and body ground. OK: Voltage: 10 − 14 V ON Tc or (−) (+) AB0118 AB0119 R14304 H00031 OK Check harness between terminal E1 of DLC1 and body ground. NG 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−282 DIAGNOSTICS 4 − SUPPLEMENTAL RESTRAINT SYSTEM Check airbag sensor assembly. LOCK ON ACC or Airbag Sensor Assembly Tc AB0117 AB0118 AB0119 R12658 H00032 PREPARATION: (a) Turn ignition switch to LOCK. (b) Disconnect negative (−) terminal cable from the battery, and wait at least 90 seconds. (c) Disconnect airbag sensor assembly connector. (d) Insert service wire into terminal Tc from back side as shown. (e) Connect airbag sensor assembly connector with service wire. (f) Connect negative (−) terminal cable to battery. (g) Turn ignition switch to ACC or ON, and wait at least 20 seconds. (h) Connect service wire of terminal Tc to body ground. CHECK: Check operation of SRS warning light. OK: SRS waning light comes on. NOTICE: Never make a mistake with the terminal connection position as this will cause a malfunction. OK Check harness between airbag sensor assembly and DLC1. NG Replace airbag sensor assembly. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−283 DIAGNOSTICS − SUPPLEMENTAL RESTRAINT SYSTEM If the DTC is displayed without a DTC check procedure, perform the following troubleshooting. 1 LOCK Check resistance between terminal Tc of airbag sensor assembly and body ground. Airbag Sensor Assembly AB0117 R14303 Tc H00033 PREPARATION: (a) Turn ignition switch to LOCK. (b) Disconnect negative (−) terminal cable from the battery, and wait at least 90 seconds. (c) Disconnect airbag sensor assembly connector. CHECK: Check resistance between terminal Tc of airbag sensor assembly connector and body ground. OK: Resistance: 1 MΩ or Higher NG Repair or replace harness or connector. OK Replace airbag sensor assembly. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−284 DIAGNOSTICS − CRUISE CONTROL SYSTEM CRUISE CONTROL SYSTEM DI5O4−02 HOW TO PROCEED WITH TROUBLESHOOTING Vehicle Brought to Workshop 1 Items inside are titles of pages in this manual with the page number indicated in the bottom portion. See the indicated pages for detailed explanations. Customer Problem Analysis P. DI−285 2 Check and Clear DTC (Precheck) P. DI−286 3 Symptom does not occur Problem Symptom Confirmation 4 Symptom Simulation P. IN−18 Symptom occurs 5 Normal code DTC Check P. DI−286 Malfunction code 6 7 DTC Chart Problem Symptom Table P. DI−295 P. DI−291 8 9 Circuit Inspection Input Signal Check Parts Inspection P. DI−306 − DI−310 Identification of Problem Repair NG 10 Confirmation Test OK Step 2, 5, 8, 10: Diagnostic steps permitting the use of the TOYOTA hand−held tester or TOYOTA break−out−box. End 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 451 Brought to you by BirfMark DI−285 DIAGNOSTICS − CRUISE CONTROL SYSTEM DI5O5−01 CUSTOMER PROBLEM ANALYSIS CHECK CRUISE CONTROL SYSTEM Check Sheet Inspector’s name: Registration No. Registration Year Customer’s Name Frame No. Date of Vehicle Brought in / / Date of Problem Occurrence / Condition of How Often does Problem Occurrence Problem Occur? Continuous Symptoms DTC Check / Intermittent ( Times a day) km Mile Vehicle Speed when Problem Occurred Auto cancel occurs km Mile Odometer Reading D Driving condition j City driving j Freeway j Up hill j Down hill D After cancel occurred, did the driver activate cruise control again? j Yes j No j Cancel does not occur j With brake ON j Except D position shift j At 40 km/h (25 mph) or less j When control SW turns to CANCEL position j Cruise control malfunction j Slip to acceleration side j Slip to deceleration side j Hunting occurs j O/D cut off does not occur j O/D does not return j Switch malfunction j SET j Cruise MAIN indicator light j Remains ON j Does not light up 1st Time j Normal Code j Malfunction Code (Code ) 2nd Time j Normal Code j Malfunction Code (Code ) j ACCEL 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 j COAST j RESUME j CANCEL j Blinking Brought to you by BirfMark DI−285 DIAGNOSTICS − CRUISE CONTROL SYSTEM DI5O5−01 CUSTOMER PROBLEM ANALYSIS CHECK CRUISE CONTROL SYSTEM Check Sheet Inspector’s name: Registration No. Registration Year Customer’s Name Frame No. Date of Vehicle Brought in / / Date of Problem Occurrence / Condition of How Often does Problem Occurrence Problem Occur? Continuous Symptoms DTC Check / Intermittent ( Times a day) km Mile Vehicle Speed when Problem Occurred Auto cancel occurs km Mile Odometer Reading D Driving condition j City driving j Freeway j Up hill j Down hill D After cancel occurred, did the driver activate cruise control again? j Yes j No j Cancel does not occur j With brake ON j Except D position shift j At 40 km/h (25 mph) or less j When control SW turns to CANCEL position j Cruise control malfunction j Slip to acceleration side j Slip to deceleration side j Hunting occurs j O/D cut off does not occur j O/D does not return j Switch malfunction j SET j Cruise MAIN indicator light j Remains ON j Does not light up 1st Time j Normal Code j Malfunction Code (Code ) 2nd Time j Normal Code j Malfunction Code (Code ) j ACCEL 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 j COAST j RESUME j CANCEL j Blinking Brought to you by BirfMark DI-286 DIAGNOSTICS - CRUISE CONTROL SYSTEM DI5O6-02 PRE-CHECK 1. (a) CRUISE MAIN Indicator Light N06218 HINT: If the indicator check result is not normal, proceed to troubleshooting (See page BE-34 ) for the combination meter section. (b) Check the DTC. HINT: If a malfunction occurs in the No. 1 vehicle speed sensors or actuator, etc. during cruise control driving, the ECU actuates AUTO CANCEL of the cruise control and turns on and off the CRUISE MAIN indicator light to inform the driver of a malfunction. At the same time, the malfunction is stopped in memory as a diagnostic trouble code. Indicator Light 1.5 sec. DIAGNOSIS SYSTEM Check the indicator. (1) Turn the ignition switch to ON. (2) Check that the CRUISE MAIN indicator light comes on when the cruise control main switch is turned on, and that the indicator light goes off when the main switch is turned OFF. 0.5 sec. ON OFF BE4034 (c) DLC1 E1 TC Output of DTC using diagnosis check wire. (1) Turn the ignition switch ON. (2) Using SST, connect terminals Tc and E1 of DLC1. SST 09843-18020 (3) Read the DTC on the CRUISE MAIN indicator light. N06219 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI-287 DIAGNOSTICS - CRUISE CONTROL SYSTEM HINT: If the DTC is not output, inspect the diagnosis circuit (See page DI-333 ) As an example, the blinking patterns for codes; normal, 11 and 21 are shown in the illustration. Normal Code 0.25 sec. 0.25 sec. ON OFF Malfunction codes 11 and 21 0.5 sec. 4 sec. 1.5 sec. 2.5 sec. 0.5 sec. 1.5 sec. ON OFF BE4032 BE4033 Code 11 Code 21 I00021 TOYOTA hand-held tester 2. (a) (b) (c) TOYOTA Break-out-box N09348 3. (a) Instrument Panel Junction Block ECU- B Fuse (b) ECU TERMINAL VALUES MEASUREMENT BY USING TOYOTA BREAK-OUT-BOX AND TOYOTA HANDHELD TESTER Hook up the TOYOTA break- out- box and TOYOTA hand-held tester to the vehicle. Read the ECU input/output values by following the prompts on the tester screen. Please refer to the TOYOTA hand-held tester has a ”Snapshot” function. This records the measured data and is effective in the diagnosis of intermittent problems. DTC CLEARANCE After completing repairs, the diagnostic trouble code retained in memory can be cleared by removing the ECU-B fuse for 10 seconds or more, with the ignition switch off. Check that the normal code is displayed after connecting the fuse. N18670 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI-288 DIAGNOSTICS - CRUISE CONTROL SYSTEM 4. (a) PROBLEM SYMPTOM CONFIRMATION (ROAD TEST) Inspect the SET switch. (1) Push the main switch ON. (2) Drive at a desired speed (40 km/h (25 mph) or higher). (3) Press the control switch to the SET/COAST. (4) After releasing the switch, check that the vehicle cruises at the desired speed. (b) Inspect the ACCEL switch. (1) Push the main switch ON. (2) Drive at a desired speed (40 km/h (25 mph) or higher). (3) Check that the vehicle speed is increased while the control switch turned to RES/ACC, and that the vehicle cruises at the set speed when the switch is released. (4) Momentarily press the control switch upward in the RES/ACC and then immediately release it. Check that the vehicle speed increases by about 1.5 km/h (Tap-up function). (c) Inspect the COAST switch. (1) Push the main switch ON. (2) Drive at a desired speed (40 km/h (25 mph) or higher). (3) Check that the vehicle speed is decreased while the control switch is turned to SET/COAST, and the vehicle cruise at the set speed when the switch is released. (4) Momentarily press the control switch is turned to SET/COAST, and then immediately release it. Check that the vehicle speed decreases by about 1.5 km/h (Tap-down function). N14305 N14305 N14305 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI-289 DIAGNOSTICS CRUISE CONTROL SYSTEM (d) Inspect the CANCEL switch. (1) Push the main switch ON. (2) Drive at a desired speed (40 km/h (25 mph) or higher). (3) When operating one of the followings, check that the cruise control system is cancelled and that the normal driving mode is reset.
Depress the brake pedal
Shift to except D position
Push the main switch OFF
Pull the cruise control switch to CANCEL (e) Inspect the RESUME switch. (1) Push the main switch ON. (2) Drive at a desired speed (40 km/h (25 mph) or higher). (3) When operating one of the followings, check that the cruise control system is cancelled and that the normal driving mode is reset.
Depress the brake pedal
Shift to except D position
Pull the cruise control switch to CANCEL (4) After the control switch is turned to RES/ACC at the driving speed of more than 40 km/h (25 mph), check that the vehicle restores the speed prior to the cancellation. N14305 N14305 - 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI-290 DIAGNOSTICS (2) No. N14305 CRUISE MAIN Indicator Light Blinking Pattern Operation Method 0.25 sec. 1 2 Turn SET/COAST switch ON Turn RES/ACC switch ON Light ON Light SET/COAST switch circuit is normal 1sec. RES/ACC switch circuit is normal OFF Light ON CANCEL switch circuit is normal Switch OFF Switch ON OFF Turn stop light switch ON Depress brake pedal ON Turn PNP switch OFF (Shift to except D position) Light Drive at about 40 km/h (25 mph)or higher Light ON OFF Drive at about 40 km/h (25 mph) or below Light OFF Diagnosis 0.25 sec. OFF ON Turn CANCEL switch ON 3 CRUISE CONTROL SYSTEM 5. INPUT SIGNAL CHECK HINT: (1) For check No.1 - No.3
Turn ignition switch ON. (2) For check No.4
Jack up the vehicle.
Start the engine.
Shift to D position. (a) Press the control switch to SET/COAST or RES/ACC position and hold it down or hold it up ”1”. (b) Push the main switch ON ”2”. (c) Check that the CRUISE MAIN indicator light blinks twice or 3 times repeatedly after 3 seconds. (d) Turn the SET/COAST or RES/ACC switch OFF. (e) Operate each switch as listed in the table below. (f) Read the blinking pattern of the CRUISE MAIN indicator light. (g) After performing the check, turn the main switch OFF. HINT: When 2 or more signals are input to the ECU, the lowest numbered code will be displayed first. (1) (1) - Stop light switch circuit is normal Switch ON Switch OFF 4 ON OFF 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 PNP switch circuit is normal Vehicle Speed Sensor is normal Brought to you by BirfMark DI−291 DIAGNOSTICS − CRUISE CONTROL SYSTEM DI5O7−02 DIAGNOSTIC TROUBLE CODE CHART If a malfunction code is displayed during the DTC check, check the circuit listed for that code in the table below and proceed to the appropriate page. DTC No. (See Page) Circuit inspection Trouble Area S Actuator Motor Circuit S Actuator motor S Harness or connector between cruise control ECU and actuator motor S Cruise control ECU S Actuator Magnetic Clutch Circuit S STOP Fuse S Stop light switch S Actuator magnetic clutch S Harness or connector between cruise control ECU and actuator magnetic clutch, actuator magnetic clutch and body ground S Cruise control ECU S Actuator Position Sensor Circuit S Actuator position sensor S Harness or connector between cruise control ECU and actuator position sensor S Cruise control ECU S Actuator Mechanical Malfunction S Actuator motor (actuator lock: motor, arm) S Harness or connector between cruise control ECU and actuator motor S Cruise control ECU 21 (DI−306) S Open in Vehicle Speed Sensor Circuit S Combination meter S Harness or connector between cruise control ECU and combination meter, combination meter and vehicle speed sensor S Vehicle speed sensor S Cruise control ECU 23 (DI−310) S Vehicle Speed Signal Abnormal S Vehicle speed sensor S Cruise control ECU S Control Switch Circuit S Cruise control switch S Harness or connector between cruise control ECU and cruise control switch, cruise control switch and body ground S Cruise control ECU 11 (DI−296) 12 (DI−298) 13 (DI−301) 14 (DI−304) 32 (DI−311) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−292 DIAGNOSTICS − CRUISE CONTROL SYSTEM DI5O8−02 PARTS LOCATION DLC1 Cruise Control Actuator  Actuator Motor  Actuator Magnetic Clutch  Actuator Position Sensor Cruise Control ECU Cruise Control Switch  Main Switch  Control Switch Stop Light Switch Instrument Panel Fuse Block  GAUGE Fuse  ECU−IG Fuse  ECU−B Fuse No.1 Vehicle Speed Sensor Park/Neutral Position Switch I00756 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−293 DIAGNOSTICS − CRUISE CONTROL SYSTEM DI5O9−02 TERMINALS OF ECM C18 Vd−26−2−E Symbols (Terminals No.) D ↔ GND (C18−2 ↔ C18−13) PI ↔ GND (C18−7 ↔ C18−13) TC ↔ GND (C18−8 ↔ C18−13) I00410 Wiring Color B−W ↔ BR G−Y ↔ BR B−Y ↔ BR OD ↔ GND (C18−9 ↔ C18−13) G−O ↔ BR L ↔ GND (C18−10 ↔ C18−13) R ↔ BR MC ↔ GND (C18−11 ↔ C18−13) MO ↔ GND (C18−12 ↔ C18−13) L−R ↔ BR L ↔ BR Condition STD Voltage (V) Shift to except D position Below 1 V Shift to D position 10 − 16 V Ignition switch ON Cruise control main switch ON Below 1.2 V Ignition switch ON Cruise control main switch OFF 10 − 16 V Ignition switch ON 10 − 16 V Ignition switch ON Connect terminals TC and E1 of diagnostic check connector Below 1 V During cruise control driving OD switch ON. 10 − 16 V During cruise control driving OD switch OFF (3rd driving) Below 1 V During cruise control driving 9 − 15 V Except during cruise control driving Below 1 V During cruise control driving COAST switch hold ON 9 − 15 V During cruise control driving ACC switch hold ON Below 1 V During cruise control driving ACC switch hold ON 9 − 15 V During cruise control driving COAST switch hold ON Below 1 V GND ↔ Body Ground (C18−13 ↔ Body Ground) BR ↔ Body Ground Constant Below 1 V B ↔ GND (C18−14 ↔ C18−13) B−W ↔ BR Ignition switch ON 10 − 16 V BATT ↔ GND (C18−15 ↔ C18−13) B−R ↔ BR Constant 10 − 16 V STP− ↔ GND (C18−16 ↔ C18−13) G−W ↔ BR Depress brake pedal 10 − 16 V Release brake pedal Below 1 V 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−294 DIAGNOSTICS Symbols (Terminals No.) CCS ↔ GND (C18−18 ↔ C18−13) Wiring Color B−G ↔ BR CMS ↔ GND (C18−19 ↔ C18−13) Y−R ↔ BR SPD ↔ GND (C18−20 ↔ C18−13) L−W ↔ BR IDL ↔ GND (C18−21 ↔ C18−13) G−W ↔ BR ECT ↔ GND (C18−22 ↔ C18−13) ECT ↔ GND (C18−22 ↔ C18−13) G−R ↔ BR VR1 ↔ GND (C18−23 ↔ C18−13) Y ↔ BR VR2 ↔ VR3 (C18−24 ↔ C18−25) Y−G ↔ Y−L − CRUISE CONTROL SYSTEM Condition STD Voltage (V) Ignition switch ON 10 − 16 V Ignition switch ON CANCEL switch hold ON 5.1 − 8.3 V Ignition switch ON SET/COAST switch hold ON 2.4 − 4.0 V Ignition switch ON RES/ACC switch hold ON 0.8 − 1.4 V Ignition switch ON Main switch ON Below 1 V Ignition switch ON Main switch OFF 10 − 16 V Ignition switch ON 4.7 − 5.2 V During driving 3−7V Ignition switch ON Throttle valve fully closed Below 1 V Ignition switch ON Throttle valve fully opened 10 − 16 V During driving Gear position O/D Below 1 V During driving Gear position 3rd 10 − 16 V Ignition switch ON 4.7 − 5.2 V During cruise control driving 1.0 − 4.7 V Ignition switch ON Actuator control plate fully opened 4.2 − 4.7 V Ignition switch ON Actuator control plate fully closed 1.0 − 1.2 V VR3 ↔ GND (C18−25 ↔ C18−13) Y−L ↔ BR Constant Below 1 V L− ↔ GND (C18−26 ↔ C18−13) ↔ BR Constant Below 1 V 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−295 DIAGNOSTICS − CRUISE CONTROL SYSTEM DI5OA−02 PROBLEM SYMPTOMS TABLE Symptom Suspect Area See page SET not occourring or CANCEL occurring. (DTC is Normal) 1. Main Switch Circuit (Cruise control switch) 2. Vehicle Speed Sensor 3. Control Switch Circuit (Cruise control switch) 4. Stop Light Switch Circuit 5. Park/Neutral Position Switch Circuit 6. Actuator Motor Circuit 7. Cruise Control Cable 8. Cruise Control ECU DI−330 DI−306 DI−311 DI−314 DI−322 DI−296 DI−336 IN−28 SET not occurring or CANCEL occurring. (DTC does not output) 1. ECU Power Source Circuit 2. Cruise Control ECU DI−325 IN−28 DI−336 DI−310 DI−319 Actual vehicle speed deviates above or below the set speed. 1. Cruise Control Cable 2. Vehicle Speed Signal Abnormal 3. Electronically Controlled Transmission Communication Circuit 4. Actuator Motor Circuit 5. Idle Signal Circuit (main throttle position sensor) 6. Cruise Control ECU Gear shifting frequent between 3rd O/D when driving on uphill road. (Hurting) 1. Electronically Controlled Transmission Communication Circuit 2. Cruise Control ECU DI−319 Cruise control not cancelled, even when brake pedal is depressed. 1. Cruise Control Cable 2. Stop Light Switch Circuit 3. Actuator Motor Circuit 4. Cruise Control ECU DI−336 DI−314 DI−296 IN−28 Cruise control not cancelled, even when transmission is shifted to ”N” postion. 1. Cruise Control Cable 2. Park/Neutral Position Switch Circuit 3. Actuator Motor Circuit 4. Cruise Control ECU DI−336 DI−322 DI−296 IN−28 Control switch does not operate. (SET/COAST, ACC/RES, CANCEL not possible) 1. Cruise Control Cable 2. Control Switch Circuit 3. Actuator Motor Circuit 4. Cruise Control ECU DI−336 DI−311 DI−296 IN−28 SET possible at 40 km/h (25 mph) or less, or CANCEL does not operate at 40 km/h (25 mph) or less. 1. Cruise Control Cable 2. Vehicle Speed Signal Abnormal 3. Actuator Motor Circuit 4. Cruise Control ECU DI−336 DI−310 DI−296 IN−28 DI−336 DI−319 Poor response is ACCEL and RESUME modes. 1. Cruise Control Cable 2. Electronically Controlled Transmission Communication Circuit 3. Actuator Motor Circuit 4. Cruise Control ECU 1. Electronically Controlled Transmission Communication Circuit 2. Cruise Control ECU DI−319 DTC memory is erased. 1. Back−up Power Source Circuit 2. Cruise Control ECU DI−328 IN−28 DTC is not output, or is output when is should not be. 1. Diagnosis Circuit 2. Cruise Control ECU DI−319 IN−28 Cruise MAIN indicator light remains ON or fall to light up. 1. Cruise MAIN Indicator Light Switch Circuit DI−332 O/D does not RESUME, even though the road is not uphill. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 DI−296 DI−316 IN−28 IN−28 DI−296 IN−28 IN−28 Brought to you by BirfMark DI−296 DIAGNOSTICS − CRUISE CONTROL SYSTEM DI5OB−02 CIRCUIT INSPECTION DTC 11 Actuator Motor Circuit CIRCUIT DESCRIPTION The actuator motor is operated by signals from the ECU. Acceleration and deceleration signals are transmitted by changes in the Duty Ratio (See note below). Duty Ratio The duty ratio is the ratio of the period of continuity in one cycle. For example, if A is the period of continuity in one cycle, and B is the period of non−continuity, then. A Duty Ratio = A+B DTC No. 11 x 100 (%) A ON OFF Detection Item B 1 cycle Trouble Area S Actuator motor S Harness or connector between cruise control ECU and actuator motor S Cruise control ECU Short in actuator motor circuit. WIRING DIAGRAM Cruise Control Actuator Cruise Control ECU 7 C4 6 C4 L−R L 11 C17 MC 12 C17 MO I00488 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−297 DIAGNOSTICS − CRUISE CONTROL SYSTEM INSPECTION PROCEDURE 1 Check resistance between terminals MO and MC of actuator motor. 6 7 I00248 PREPARATION: (a) Turn ignition switch OFF. (b) Disconnect the actuator connector. CHECK: Measure resistance between terminals 6 and 7. HINT: If control plate position is fully opened or fully closed, resistance can not measure. OK: Resistance: more than 4.2 Ω NG Replace cruise control actuator. OK 2 Check for open and short in harness and connectors between cruise control ECU and actuator motor (See page IN−28). NG Repair or replace harness or connector. OK Check and replace cruise control ECU. (See page IN−28). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−298 DIAGNOSTICS − CRUISE CONTROL SYSTEM DI5OC−02 DTC 12 Actuator Magnetic Clutch Circuit CIRCUIT DESCRIPTION This circuit turns on the magnetic clutch inside the actuator during cruise control operation according to the signal from the ECU. If a malfunction occurs in the actuator or speed sensor, etc. during cruise control operation, the rotor shaft between the motor and control plate is released. When the brake pedal is depressed, the stop light switch turns on, supplying electrical power to the stop light. Power supply to the magnetic clutch is mechanically cut and the magnetic clutch is turned OFF. When driving downhill, if the vehicle speed exceeds the set speed by 15 km/h (9 mph), the ECU turns the safety magnet clutch OFF. If the vehicle speed later drops to within 10 km/h (6 mph) above the set speed, then cruise control at the set speed is resumed. DTC No. 12 Detection Item Trouble Area S STOP Fuse S Stop light switch S Actuator magnetic clutch S Harness or connector between cruise control ECU and actuator magnetic clutch, actuator magnetic clutch and body ground S Cruise control ECU S Short in actuator magnetic clutch circuit. S Open (0.8 sec.) in actuator magnetic clutch circuit. WIRING DIAGRAM Cruise Control ECU 26 W−B Cruise Control Actuator 5 C4 4 C4 W 3 EA3 1 STOP F11 R−G 2 F11 G−O C17 Stop Light Switch 3 4 S13 2 S13 S13 1 S13 R G−W 10 L− C17 L C17 STP− Instrument Panel Fuse Block W F8 FL MAIN 1 Fusible Link Battery I00489 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−299 DIAGNOSTICS − CRUISE CONTROL SYSTEM INSPECTION PROCEDURE 1 Check STOP fuse. PREPARATION: (a) Turn ignition switch OFF. (b) Remove the STOP fuse from instrument panel fuse block. CHECK: Check fuse continuity. OK: There is continuity. Instrument Panel Fuse Block STOP Fuse N18670 NG Replace STOP fuse. OK 2 Check stop light switch. 2 4 1 PREPARATION: Disconnect the stop light switch connector. CHECK: Check continuity between terminals. 3 I00133 NG Switch position Continuity Switch pin free (Brake pedal depressed) 1−2 Switch pin pushed in (Brake pedal released) 3−4 Replace stop light switch. OK 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−300 DIAGNOSTICS 3 − CRUISE CONTROL SYSTEM Check resistance between terminals L and GND of actuator magnetic clutch. PREPARATION: (a) Turn ignition switch OFF. (b) Disconnect the actuator connector. CHECK: Measure resistance between terminals 4 and 5. OK: Resistance: 34.65 − 42.35 Ω. 4 5 I00247 NG Replace cruise control actuator. OK 4 Check for open and short in harness and connectors between cruise control ECU and actuator magnetic clutch, actuator magnetic clutch and body ground (See page IN−28). NG Repair or replace harness or connector. OK Check and replace cruise control ECU (See page IN−28). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−301 DIAGNOSTICS − CRUISE CONTROL SYSTEM DI5OD−02 DTC 13 Actuator Position Sensor Circuit CIRCUIT DESCRIPTION The circuit detects the rotation position of the actuator control plate and sends a signal to the ECU. DTC No. S 13 Detection Item Trouble Area S Actuator position sensor S Harness or connector between cruise control ECU and actuator position sensor S Cruise control ECU S Position sensor detects abnormal voltage. WIRING DIAGRAM Cruise Control Actuator Cruise Control ECU 3 C4 2 C4 1 C4 Y−L Y−G Y 25 C17 VR3 24 C17 VR2 23 C17 VR1 I00490 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−302 DIAGNOSTICS − CRUISE CONTROL SYSTEM INSPECTION PROCEDURE 1 Check resistance between terminals VR2 and VR3 of cruise control ECU connector. Fully Close Side ON Fully Open Side Control Plate (+) VR3 (−) VR2 AB0119 I00130 I00135 PREPARATION: (a) Remove the ECU with connectors still connected. (b) Turn ignition switch OFF. CHECK: Measure voltage between terminals VR2 and VR3 of ECU connector while turning control plate slowly by hand from the deceleration side to the acceleration side. OK: Voltage: Fully closed: Approx. 1.3 V Fully opened: Approx. 4.1 V In addition, as the control plate is turned, the voltage should increase gradually without interruption. I00161 NG Proceed to next circuit inspection shown on problem symptoms table (See page DI−295). OK 2 Check resistance between terminals VR1 and VR3 of actuator position sensor. PREPARATION: (a) Turn ignition switch OFF. (b) Disconnect the actuator connector. CHECK: Measure resistance between actuator terminal 1 and 3 of actuator connector. OK: Resistance: 1.8 − 2.2 kΩ (25 °C) 1 3 I00006 NG Replace cruise control actuator. OK 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−303 DIAGNOSTICS 3 2 − CRUISE CONTROL SYSTEM Check voltage between terminals VR2 and VR3 of actuator position sensor. PREPARATION: (a) Turn ignition switch ON. (b) Connect the actuator connector. CHECK: Measure voltage between terminals 2 and 3 of actuator connector while turning control plate slowly by hand from the deceleration side to the acceleration side. OK: Voltage: 1.3 − 4.0 V HINT: As the control plate is turned, the voltage should increase gradually without interruption. 3 I00007 NG Replace cruise control actuator. OK 4 Check for open and short in harness and connector between cruise control ECU and actuator position sensor (See page IN−28). NG Repair or replace harness or connector. OK Check and replace cruise control ECU (See page IN−28). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−304 DIAGNOSTICS − CRUISE CONTROL SYSTEM DI5OE−02 DTC 14 Actuator Mechanical Malfunction CIRCUIT DESCRIPTION The circuit detects the rotation position of the actuator control plate and sends a signal to the ECU. DTC No. 14 Detection Item Trouble Area S Open in actuator motor circuit. S Position sensor signal valve does not change when the motor operates. S Actuator lock: (motor, arm) S Actuator motor S Harness or connector between cruise control ECU and actuator motor S Cruise control ECU WIRING DIAGRAM See page DI−296. INSPECTION PROCEDURE 1 Check cruise control actuator arm locking operation 4 (+) (−) 5 I00054 PREPARATION: (a) Turn ignition switch OFF. (b) Disconnect the actuator connector. CHECK: (a) Connect the positive (+) lead from the battery to the terminal 5 of actuator and the negative (−) lead to terminal 4. NOTICE: Do not connect the high tension cables to the wrong battery terminal. You will damage the cruise control actuator. (b) Move the control plate by hand. OK: Control plate does not move. NG Replace cruise control actuator. OK 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−305 DIAGNOSTICS 2 − CRUISE CONTROL SYSTEM Check cruise control actuator operation. PREPARATION: (a) Turn ignition switch OFF. (b) Disconnect the actuator connector. CHECK: Connect the positive (+) lead from the battery to terminals 5 and 6 of actuator, connect the negative (−) lead to terminals 4 and 7 of actuator. OK: Control arm moves to full open side CHECK: Connect the positive (+) lead from the battery to terminals 4 and 7of actuator, connect the negative (−) lead to terminals 5 and 6 of actuator. OK: Control arm moves to full colse side Fully open side 5 Control plate 4 7 6 Fully close side 5 7 4 6 Control Plate I00131 I00008 I00132 I00010 I00132 NG Replace cruise control actuator. OK 3 Check harness and connector between cruise control ECU and cruise control actuator (See page IN−28). NG Repair or replace harness or connector. OK Check and replace cruise control ECU (See page IN−28). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−306 DIAGNOSTICS − CRUISE CONTROL SYSTEM DI5OF−02 DTC 21 Open in Vehicle Speed Sensor Circuit CIRCUIT DESCRIPTION The vehicle speed sensor circuit is sent to cruise control ECU as vehicle speed signal. The rotor shaft is driven by the gear of the transmission. For each rotation of the shaft, the vehicle speed sensor sends a 4 pulse signal through the combination meter to the cruise control ECU (See the following). This signal is converted inside the combination meter and sent as a 4−pulse signal to the cruise control ECU. The ECU calculates the vehicle speed from this pulse frequency. 4 pulse/ 1 rotation of rotor shaft 4 pulse/ 1 rotation of rotor shaft Vehicle Speed Sensor OD/TRIP METER ECT DTC No. 21 Detection Item Cruise Control ECU I00414 Trouble Area S Speed signal is not input to the cruise control ECU while cruise control is set. S Combination meter S Harness or connector between cruise control ECU and combination meter, combination meter and vehicle speed sensor S Vehicle speed sensor S Cruise control ECU 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−307 − DIAGNOSTICS CRUISE CONTROL SYSTEM WIRING DIAGRAM 2 R−G 3 V1 R−G Ea1 2 EC1 BR 3 R−O IH1 9 BR Ea1 Ea1 C13 C13 20 L−W C17 SPD BR EC1 EC V1 J4 JUNCTION CONNECTOR Y B B Y Y 1 1 R−O Cruise Control ECU Vehicle Speed Sensor (Combination Meter) V1 1 5 Speedometer (Combination Meter) 3 4 3 Y EC1 Y 6 IH1 Air Intake Chamber 3 GAUGE 1 F11 F11 B−Y Instrument Panel Fuse Block 2 3 4 2 W 2 AM1 2 B 2 4 I12 I12 Ignition Switch B 6 EA1 B−L Battery 1 F6 FL MAIN Fusible Link I00491 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−308 DIAGNOSTICS − CRUISE CONTROL SYSTEM INSPECTION PROCEDURE 1 Input signal check. Indicator Light Blinking Pattern Input Signal Drive at about 40 km/h (25 mph) or below Light Drive at about 40 km/h (25 mph) or higher Light ON OFF ON OFF CHECK: (a) See input signal check on page DI−286. (b) Check indicator light operation when driving with vehicle speed above 40 km/h (25 mph), and with vehicle speed below 40 km/h (25 mph). OK: Vehicle speed above 40 km/h (25 mph): Indicator light blinks Vehicle speed below 40 km/h (25 mph): Indicator light stays on OK Check and replace cruise control ECU (See page IN−28). NG 2 Check speedometer circuit (See Combination meter troubleshooting on page BE−34). NG Repair or replace harness, connector or combination meter assembly. OK 3 Check harness and connector between cruise control ECU and combination meter, combination meter and vehicle speed sensor (See page IN−28). NG Repair or replace harness or connector. OK 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−309 DIAGNOSTICS 4 − CRUISE CONTROL SYSTEM Check vehicle speed sensor (See page BE−34). NG Replace vehicle speed sensor. OK Check and replace cruise control ECU (See page IN−28). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−310 DIAGNOSTICS − CRUISE CONTROL SYSTEM DI5OG−02 DTC 23 Vehicle Speed Signal Abnormal CIRCUIT DESCRIPTION See page DI−306. DTC No. Detection Item Trouble Area 23 S Vehicle speed sensor pulse is abnormal. (When speed signal is not input to the ECU below 0.2 sec., code will be displayed.) S Vehicle speed sensor S Cruise control ECU WIRING DIAGRAM See page DI−306. INSPECTION PROCEDURE 1 Check vehicle speed sensor (See page BE−34). NG Replace vehicle speed sensor. OK Check and replace cruise control ECU (See page IN−28). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−311 DIAGNOSTICS − CRUISE CONTROL SYSTEM DI5OH−02 DTC 32 Control Switch Circuit (Cruise Control Switch) CIRCUIT DESCRIPTION This circuit carries the SET/COAST, RESUME/ACCEL and CANCEL signals (each voltage) to the ECU. DTC No. 32 Detection Item Trouble Area S Cruise control switch S Harness or connector between cruise control ECU and cruise control switch, cruise control switch and body ground S Cruise control ECU S Short in control switch circuit. WIRING DIAGRAM Cruise Control Switch MAIN Cruise Control ECU 15 Y−R C15 19 C17 CMS CANCEL SET/COAST RESUME/ ACCEL 5 B−G C15 C15 18 C17 CCS 20 BR BR 17 C17 GND BR ID I00492 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−312 DIAGNOSTICS − CRUISE CONTROL SYSTEM INSPECTION PROCEDURE 1 Input signal check. Input Signal SET/COAST switch RESUME/ACCEL switch CANCEL switch Indicator Light Blinking Pattern 2 Pulses ON OFF 3 Pulses ON OFF ON SW OFF OFF SW ON PREPARATION: See input signal check on page DI−286. CHECK: Check the indicator light operation when each of the SET/ COAST, RESUME/ACCEL and CANCEL is turned on. OK: SET/COAST, RESUME/ACCEL switch The signals shown in the table on the left should be output when each switch is ON. The signal should disappear when the switch is turned OFF. CANCEL switch The indicator light goes off when the cancel switch is turned ON. OK Wait and see. NG 2 Check voltage between terminals CCS of cruise control ECU connector and body ground. PREPARATION: (a) Remove the ECU with connector still connected. (b) Turn ignition switch ON. CHECK: Measure voltage between terminals CCS of ECU connector and body ground, when each of the SET/COAST, RESUME/ ACCEL and CANCEL is turned ON. ON CCS (−) (+) AB0119 Switch position Resistance (Ω) Neutral 10 − 14 V RES/ACC 0.7 − 2.5 V SET/COAST 2.3 − 4.6 V CANCEL 4.1 − 7.2 V I00136 I00162 NG Proceed to next circuit inspection shown on problem symptoms table (See page DI−295) OK 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−313 DIAGNOSTICS 3 − CRUISE CONTROL SYSTEM Check control switch. 4 PREPARATION: (a) Remove steering wheel center pad. (b) Disconnect the control switch connector. CHECK: Measure resistance between terminals 3 and 4 of control switch connector when control switch is operated. 3 N16045 NG Switch position Resistance (Ω) Neutral ∞ (No continuity) RES/ACC 50 − 80 SET/COAST 180 − 220 CANCEL 400 − 440 Replace control switch. OK 4 Check harness and connector between cruise control ECU and cruise control switch, cruise control switch and body ground (See page IN−28). NG Repair or replace harness or connector. OK Wait and see. OK 5 Input signal check (See step 1). NG Check and replace cruise control ECU (See page IN−28). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−314 DIAGNOSTICS − CRUISE CONTROL SYSTEM DI5OI−02 Stop Light Switch Circuit CIRCUIT DESCRIPTION When the brake pedal is depressed, the stop light switch sends a signal to the ECU. When the ECU receives this signal, it cancels the cruise control. A fail−safe function is provided so that the cancel functions normally, even if there is a malfunction in the stop light signal circuit. The cancel conditions are: Battery positive voltage at terminal STP− When the brake is on, battery positive voltage normally applies through the STOP fuse and stop light switch to terminal STP− of the ECU, and the ECU turns the cruise control off. If the harness connected to terminal STP− has an open circuit, terminal STP− will have battery positive voltage and the cruise control will be turned off. Also, when the brake is on, the magnetic clutch circuit is cut mechanically by the stop light switch, turning the cruise control off (See page DI−298 for operation of the magnetic clutch). WIRING DIAGRAM See page DI−298. INSPECTION PROCEDURE 1 Check operation of stop light. CHECK: Check that stop light comes on when brake pedal is depressed, and turns off when brake pedal is released. NG Check stop light system (See page BE−24). OK 2 Input signal check. Input Signal Stop Light switch ON Indicator Light Blinking Pattern Light SW OFF ON SW ON OFF CHECK: (a) See input signal check on DI−286. (b) Check the indicator light when the brake pedal is depressed. OK: The indicator light goes off when the brake pedal is depressed. OK Proceed to next circuit inspection shown on problem symptoms table (See page DI−295). NG 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−315 DIAGNOSTICS 3 − CRUISE CONTROL SYSTEM Check voltage between terminal STP− of cruise control ECU connector and body ground. ON PREPARATION: (a) Remove the ECU with connectors still connected. (b) Turn ignition switch ON. CHECK: Measure voltage between terminal STP− of cruise control ECU connector and body ground, when the brake pedal is depressed and released. OK: STP− (−) (+) AB0119 I00015 I00024 OK Depressed 10 − 14 V Released Below 1 V Proceed to next circuit inspection shown on problem symptoms table (See page DI−295). NG 4 Check for open in harness and connectors between terminal STP− of cruise control ECU and stop light switch (See page IN−28). NG Repair or replace harness or connector. OK Check and replace cruise control ECU (See page IN−28). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−316 DIAGNOSTICS − CRUISE CONTROL SYSTEM DI5OJ−02 Idle Switch Circuit CIRCUIT DESCRIPTION When the idle switch in turned ON, a signal is sent to the ECU. The ECU uses this signal to correct the discrepancy between the throttle valve position and the actuator position sensor value to enable accurate cruise control at the set speed. If the idle switch is malfunctioning, problem symptoms also occur in the engine, so also inspect the engine. WIRING DIAGRAM Cruise Control ECU ECM 11 IDL E5 G−W G−W 19 IH1 G−W 21 C17 IDL Threottle Position Sensor I00493 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−317 DIAGNOSTICS − CRUISE CONTROL SYSTEM INSPECTION PROCEDURE 1 Check voltage between terminal IDL of cruise control ECU connector and body ground. PREPARATION: (a) Remove the ECU with connector still connected. (b) Disconnect the ECM and ABS ECU connectors. (c) Turn ignition switch ON. CHECK: Measure voltage between terminal IDL of ECU connector and body ground when the throttle valve is fully closed and fully opened. OK: ON IDL (−) (+) AB0119 I00053 Throttle valve position Voltage Fully opened 10 − 14 V Fully closed Below 2 V I00031 OK Proceed to next circuit inspection shown on problem symptoms table (See page DI−295). NG 2 Check harness and connector between ECM and throttle position sensor (See page IN−28). NG Repair or replace harness or connector. OK 3 Check throttle position sensor circuit (See page DI−35). NG Replace throttle position sensor. OK 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−318 DIAGNOSTICS 4 − CRUISE CONTROL SYSTEM Check throttle position sensor. PREPARATION: Disconnect the throttle position sensor connector. CHECK: Measure resistance between terminals 3 and 4 of throttle position sensor connector when the throttle valve is fully closed and fully opened. OK: Throttle Position Sensor 3 4 I00052 NG Throttle valve position Resistance Fully opened 1 MΩ or higher Fully closed Below 2.3 kΩ Replace throttle position sensor. OK 5 Check for open and short in harness and connector between cruise control ECU and throttle position sensor, throttle position sensor and body ground (See page IN−28). NG Repair or replace harness or connector. OK Check and replace cruise control ECU (See page IN−28). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−319 − DIAGNOSTICS CRUISE CONTROL SYSTEM DI5OK−02 Electronically Controlled Transmission Communication Circuit CIRCUIT DESCRIPTION When driving uphill under cruise control, in order to reduce shifting due to ON−OFF overdrive operation and to provide smooth driving, when down shifting in the electronically controlled transmission occurs, a signal to prevent upshift until the end of the up hill slope is sent from the cruise control ECU to the electronically controlled transmission. Terminal ECT of the cruise control ECU detects the shift change signal (output to electronically controlled transmission No. 2 solenoid) from the ECM. If vehicle speed down, also when terminal ECT of the cruise control ECU receives down shifting signal, it sends a signal from terminal OD to ECM to cut overdrive until the end of the uphill slope, and the gear shifts are reduced and gear shift points in the electronically controlled transmission are changed. WIRING DIAGRAM Cruise Control ECU ECM 18 OD1 E7 9 S2 E4 9 C17 G−O R−Y R−Y 15 IH2 22 C17 ECT G−R OD 2 EC2 R−Y Ellectronically Controlled Transmission Solenoid I00494 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−320 DIAGNOSTICS − CRUISE CONTROL SYSTEM INSPECTION PROCEDURE 1 Check operation of overdrive. PREPARATION: Test drive after engine warms up. CHECK: Check that overdrive ON ↔ OFF occurs with operation of OD switch ON−OFF. NG Check and repair electronically controlled transmission (See page DI−129). OK 2 Check voltage between terminal OD of harness side connector of cruise control ECU and body ground. PREPARATION: (a) Remove the ECU with connector still connected. (b) Turn ignition switch ON. (c) Disconnect the ECU connector. CHECK: Measure voltage between terminal OD of harness side connector of ECU and body ground. OK: Voltage: 10 − 14 V ON (−) (+) OD AB0119 I00012 I00025 NG Go to step 5. OK 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−321 DIAGNOSTICS 3 − CRUISE CONTROL SYSTEM Check voltage between terminal ECT of cruise control ECU connector and body ground (On test drive). PREPARATION: (a) Connect the ECU connector. (b) Test drive after engine warms up. CHECK: Check voltage between terminal ECT of ECU connector and body ground when OD switch is ON and OFF. OK: ECT (−) (+) I00019 OK OD switch position Voltage ON 8 − 14 V OFF Below 0.5 V Proceed to next circuit inspection shown on problem symptoms table (See page DI−295). NG 4 Check harness and connector between terminal ECT of cruise control ECU and electronically controlled transmission solenoid (See page IN−28). NG Repair or replace harness or connector. OK Check and replace cruise control ECU. 5 Check harness and connector between terminal OD of cruise control ECU and terminal OD1 of ECM (See page IN−28). NG Repair or replace harness or connector. OK Check and replace cruise control ECU (See page IN−28). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−322 DIAGNOSTICS − CRUISE CONTROL SYSTEM DI5OL−02 Park/Neutral Position Switch Circuit CIRCUIT DESCRIPTION When the shift position is put in except D position, a signal is sent from the park/neutral position switch to the ECU. When this signal is input during cruise control driving, the ECU cancels the cruise control. WIRING DIAGRAM Y J4 JUNCTION CONNECTOR B Y B 6 IH1 A/T Indicator Light (Park/Neutral Position Switch) 9 4 B Y B−O P1 P1 D Cruise Control ECU 4 IH2 B−O 2 C17 D GAUGE 3 F11 Instrument Panel Fuse Block 1 F11 B−Y Fusible Link 2 I12 4 I12 B 6 EA2 2 Ignition Switch AM1 2 2 1 W Fusible Link FL AM1 1 F6 B−L 2 2 Battery I00495 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−323 DIAGNOSTICS − CRUISE CONTROL SYSTEM INSPECTION PROCEDURE 1 Check starter operation. CHECK: Check that the starter operates normally and that the engine starts. NG Proceed to engine troubleshooting (See page DI−1). OK 2 Input signal check. Input Signal Indicator Light Blinking Pattern Turn PNP switch ON SW ON Light OFF (Shift to SW OFF except D position) OFF PREPARATION: See input signal check on page DI−286. CHECK: Check the indicator light when shifting into except D position. OK: The indicator light goes off when shifting into except D position. OK Proceed to next circuit inspection shown on problem symptoms table (See page DI−295). NG 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−324 DIAGNOSTICS 3 − CRUISE CONTROL SYSTEM Check voltage between terminal D of cruise control ECU connector and body ground. ON PREPARATION: Turn ignition switch ON. CHECK: Measure voltage between terminal D of ECU connector and body ground when shifting into D position and other positions. OK: D (−) (+) AB0119 I00017 I00026 OK Shift Position Voltage D position 10 − 14 V Other positions Below 1 V Proceed to next circuit inspection shown on problem symptoms table (See page DI−295). NG 4 Check harness and connector between cruise control ECU and park/neutral position switch (See page IN−28). NG Repair or replace harness or connector. OK Check and replace cruise control ECU (See page IN−28). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−325 DIAGNOSTICS − CRUISE CONTROL SYSTEM DI5OM−02 ECU Power Source Circuit CIRCUIT DESCRIPTION The ECU power source supplies power to the actuator and sensors, etc.. When terminal GND and the cruise control ECU case are grounded. WIRING DIAGRAM Cruise Control ECU Instrument Panel Fuse Block B 6 EA2 4 I12 2 I12 B−Y F11 ECU−IG F11 Ignition Switch B 2 B−W B−W B B J6 JUNCTION CONNECTOR 14 C17 B 2 AM1 1 Fusible Link 2 2 3 BR 13 C17 GND 4 2 1 F6 FL AM1 BR Fusible Link Battery ID I00496 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−326 DIAGNOSTICS − CRUISE CONTROL SYSTEM INSPECTION PROCEDURE 1 Check ECU−B fuse. PREPARATION: Remove the ECU−B fuse from instrument panel fuse block. CHECK: Check continuity of ECU−B fuse. OK: Continuity Junction Block No.1 ECU−B Fuse N18670 NG Check for short in all the harness and components connected to ECU−B fuse. OK 2 Check voltage between terminals B and GND of cruise control ECU connector. PREPARATION: (a) Remove the ECU with connector still connected. (b) Turn ignition switch ON. CHECK: Measure voltage between terminals B and GND of ECU connector. OK: 10 − 14 V ON GND B (−) AB0119 I00014 (+) I00027 OK Proceed to next circuit inspection shown on problem symptoms table (See page DI−295). NG 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−327 DIAGNOSTICS 3 − CRUISE CONTROL SYSTEM Check resistance between terminal GND of cruise control ECU connector and body ground (See page IN−28). CHECK: Measure resistance between terminal GND of ECU connector and body ground. OK: Resistance: Below 1 Ω GND I00018 NG Repair or replace harness or connector. OK Check and repair harness and connector between cruise control ECU and battery (See page IN−28). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−328 DIAGNOSTICS − CRUISE CONTROL SYSTEM DI5ON−02 Back−up Power Source Circuit CIRCUIT DESCRIPTION The ECU back−up power source provides power even when the ignition is off and is used for DTC memory, etc.. WIRING DIAGRAM Fusible Link FL MAIN 1 F8 Cruise Control ECU Instrument Panel Fuse Block 3 EA3 W W F11 ECU−B 2 F11 B−R 15 C17 BATT Battery I00497 INSPECTION PROCEDURE 1 Check ECU−IG fuse. Junction Block No.1 ECU−IG Fuse PREPARATION: Remove the ECU−IG fuse from relay block No.2. CHECK: Check continuity of ECU−IG fuse. OK: Continuity N18670 NG Check for short in all the harness and components connected to the ECU−IG fuse. OK 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−329 DIAGNOSTICS 2 − CRUISE CONTROL SYSTEM Check voltage between terminal BATT of cruise control ECU connector and body ground (See page IN−28). PREPARATION: Remove the ECU with connector still connected. CHECK: Measure voltage between terminal BATT of ECU connector and body ground. OK: Voltage: 10 − 14 V BATT (−) (+) I00016 OK Proceed to next circuit inspection shown on problem symptoms table (See page DI−295). NG Check and repair harness and connector between battery and cruise control ECU (See page IN−28). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−330 DIAGNOSTICS − CRUISE CONTROL SYSTEM DI5OO−02 Main Switch Circuit (Cruise Control Switch) CIRCUIT DESCRIPTION When the cruise control main switch is turned off, the cruise control does not operate. WIRING DIAGRAM See page DI−311. INSPECTION PROCEDURE 1 Check voltage between terminal CMS of cruise control ECU connector and body ground. ON PREPARATION: (a) Remove the ECU with connector still connected. (b) Turn ignition switch ON. CHECK: Measure voltage between terminal CMS of cruise control ECU connector when main switch is held on and off. OK: CMS (−) (+) AB0119 I00013 I00028 OK Main switch Voltage OFF 10 − 14 V ON Below 2 V Proceed to next circuit inspection shown on problem symptoms table (See page DI−295). NG 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−331 DIAGNOSTICS 2 − CRUISE CONTROL SYSTEM Check main switch continuity. 3 PREPARATION: (a) Remove steering wheel center pad (See page SR−11). (b) Disconnect the control switch connector. CHECK: Check continuity between terminals 3 and 5 of control switch connector when main switch is held on and off. OK: 5 Switch position Tester connection Specified condition OFF 3−5 No continuity Hold ON 3−5 Continuity N15969 NG Replace control switch. OK 3 Check harness and connector between cruise control ECU and main switch (See page IN−28). NG Repair or replace harness or connector. OK Check and replace cruise control ECU (See page IN−28). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−332 DIAGNOSTICS − CRUISE CONTROL SYSTEM DI5OP−02 CRUISE MAIN Indicator Light Circuit CIRCUIT DESCRIPTION When the cruise control main switch is turned ON, CRUISE MAIN indicator light lights up. WIRING DIAGRAM J1 JUNCTION Instrument Panel Fuse Block CONNECTOR 2 GAUGE Y Y F11 F11 Cruise Control ECU 9 C10 C10 7 C17 PI G−Y CRUISE MAIN Indicator (Combination Meter) 2 I12 4 I12 6 EA2 B B AM1 2 1 2 Ignition Switch 2 W Battery Fusible Link AM1 F6 B−L 2 4 3 2 I00498 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−333 DIAGNOSTICS − CRUISE CONTROL SYSTEM INSPECTION PROCEDURE 1 Check voltage between terminals PI and GND of cruise control ECU connector. PREPARATION: Turn ignition switch ON. CHECK: Measure voltage between terminals PI and GND of ECU connector when main switch on and off. OK: ON PI (−) Switch position Voltage OFF 10 − 16 V ON Below 1.2 V (+) AB0119 I00020 I00029 OK Proceed to next circuit inspection shown on problem symptoms table (See page DI−295). NG 2 Check combination meter (See page BE−34). NG Replace combination meter. OK Check and replace cruise control ECU (See page IN−28). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−334 DIAGNOSTICS − CRUISE CONTROL SYSTEM DI5OQ−02 Diagnosis Circuit CIRCUIT DESCRIPTION This circuit sends a signal to the ECU that DTC output is required. WIRING DIAGRAM Cruise Control ECU DLC1 11 TC B−Y D1 11 B−Y IH1 8 C17 TC I00499 INSPECTION PROCEDURE 1 Check voltage between terminals Tc and E1 of DLC1. PREPARATION: Turn ignition switch ON. CHECK: Measure voltage between terminals Tc and E1 of DLC1. OK: Voltage: 10 − 14 V DLC1 TC E1 N06219 OK Proceed to next circuit inspection shown on problem symptoms table (See page DI−295). NG 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−335 DIAGNOSTICS 2 − CRUISE CONTROL SYSTEM Check harness and connector between cruise control ECU and DLC1, DLC1 and body ground (See page IN−28). NG Repair or replace harness or connector. OK Check and replace cruise control ECU (See page IN−28). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark DI−336 DIAGNOSTICS − CRUISE CONTROL SYSTEM DI5OR−01 Actuator Control Cable INSPECTION PROCEDURE 1 Actuator control cable inspection CHECK: (a) Check that the actuator, control cable throttle link are properly installed and that the cable and link are connected correctly. (b) Check that the actuator and bell crank are operating smoothly. (c) Check that the cable is not loose or too tight. OK: Freeplay: less than 10 mm HINT: S If the control cable is very loose, the vehicle’s loss of speed going uphill will be large. S If the control cable is too tight, the idle RPM will become high. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark EC−1 EMISSION CONTROL − EMISSION CONTROL SYSTEM EMISSION CONTROL SYSTEM EC07H−06 PURPOSE The emission control systems are installed to reduce the amount of HC, CO and NOx exhausted from the engine ((3), (4) and (5)), to prevent the atmospheric release of blow−by gas−containing HC (1) and evaporated fuel containing HC being released from the fuel tank (2). The function of each system is shown in the following table. System (1) Positive Crankcase Ventilation (2) Evaporative Emission Control (3) Exhaust Gas Recirculation (4) Three−Way Catalytic Converter (5) Sequential Multiport Fuel Injection* Abbreviation PCV EVAP EGR TWC SFI Function Reduces HC Reduces evaporated HC Reduces NOx Reduces HC, CO and NOx Injects a precisely timed, optimum amount of fuel for reduced exhaust emissions Remark: * For inspection and repair of the SFI system, refer to the SF section in this manual. 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 614 Brought to you by BirfMark EC−2 EMISSION CONTROL − PARTS LAYOUT AND SCHEMATIC DRAWING PARTS LAYOUT AND SCHEMATIC DRAWING EC07I−06 LOCATION 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 615 Brought to you by BirfMark EC−3 EMISSION CONTROL − PARTS LAYOUT AND SCHEMATIC DRAWING EC07J−05 DRAWING 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark EC−4 EMISSION CONTROL − POSITIVE CRANKCASE VENTILATION (PCV) SYSTEM POSITIVE CRANKCASE VENTILATION (PCV) SYSTEM INSPECTION 1. (a) (b) 2. EC0G9−01 REMOVE PCV VALVE Disconnect the PCV hose from the PCV valve. Remove the PCV valve. INSTALL CLEAN HOSE TO PCV VALVE 3. (a) INSPECT PCV VALVE OPERATION Blow air into the cylinder head side, and check that air passes through easily. CAUTION: Do not suck air through the valve. Petroleum substances inside the valve are harmful. (b) Blow air into the air intake chamber side, and check that air passes through with difficulty. If operation is not as specified, replace the PCV valve. 4. REMOVE CLEAN HOSE FROM PCV VALVE 5. REINSTALL PCV VALVE 6. VISUALLY INSPECT HOSE, CONNECTIONS AND GASKETS Check for cracks, leaks or damage. 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 617 Brought to you by BirfMark EC−5 EMISSION CONTROL − EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM EC0GA−01 COMPONENTS 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 618 Brought to you by BirfMark EC−6 EMISSION CONTROL − EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM INSPECTION 1. Look 2. Look EC0GB−01 VISUALLY INSPECT LINES AND CONNECTIONS for loose connections, sharp bends or damage. VISUALLY INSPECT FUEL TANK for deformation, cracks or fuel leakage. 3. VISUALLY INSPECT FUEL TANK CAP Check if the cap and/or gasket are deformed or damaged. If necessary, repair or replace the cap. Gasket Check Valve (Vacuum Valve) EC3069 4. (a) (b) (c) (d) 5. (a) (b) INSPECT TVV OPERATION WITH COLD ENGINE The engine coolant temperature should be below 45°C (113°F). Disconnect the EVAP hose from the union pipe. Start the engine. Gradually increase the engine speed from idle to 3,000 rpm and check that air suction is not felt at the union pipe. INSPECT OPERATION OF VCV WITH HOT ENGINE Warm up the engine. With the engine idling, check that air suction is not felt at union pipe. (c) Gradually increase the engine speed to 3,000 rpm and check that there is air suction at the union pipe. (d) Reconnect the EVAP hose to the union pipe. If no problem is found with this inspection, system is normal; otherwise inspect each part. 6. REMOVE CHARCOAL CANISTER WITH BRACKET 7. REMOVE CHARCOAL CANISTER FROM BRACKET 8. REMOVE CAP FROM CHARCOAL CANISTER 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark EC−7 EMISSION CONTROL − EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM 9. VISUALLY INSPECT CHARCOAL CANISTER Look for cracks or damage. 10. (a) INSPECT FOR CLOGGED FILTER AND STUCK VALVE Using low pressure compressed air (7.26 kPa, 74 gf/cm2, 1.05 psi), blow into tank pipe and check that air flows without resistance from the other pipes. (b) While holding drain pipe closed, blow air (1.96 kPa, 20 gf/ cm2, 0.28 psi) into purge pipe and check that air flow without resistance from tank pipe. If a problem is found, replace the charcoal canister. 11. CLEAN FILTER IN CANISTER Clean the filter by blowing 294 kPa (3 kgf/cm2, 43 psi) of compressed air into tank pipe while holding purge pipe closed. NOTICE: Do not attempt to wash the canister.No activated carbon should come out. 12. REINSTALL CAP TO CHARCOAL CANISTER 13. REINSTALL CHARCOAL CANISTER TO BRACKET Torque: 14 N·m (145 kgf·cm, 10 ft·lbf) 14. REINSTALL CHARCOAL CANISTER WITH BRACKET Torque: 18 N·m (185 kgf·cm, 13 ft·lbf) 15. DRAIN ENGINE COOLANT 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark EC−8 EMISSION CONTROL − EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM 16. (a) (b) REMOVE TVV FROM CYLINDER HEAD Disconnect the 2 vacuum hoses. Remove the TVV. 17. (a) (b) INSPECT TVV OPERATION Cool the TVV to below 45°C (113°F) with cool water. Check that air flows from pipe J to the air filter. (c) Heat the TVV to above 64°C (147°F) with hot water. (d) Check that air flows from pipe J to pipe K. If operation is not as specified, replace the TVV. 18. (a) (b) 19. REINSTALL TVV Apply adhesive to 2 or 3 threads of the TVV, and install it. Adhesive: Part No. 08833−00070, THREE BOND 1324 or equivalent Torque: 29 N·m (300 kgf·cm, 22 ft·lbf) Reconnect 2 vacuum hoses. REFILL WITH ENGINE COOLANT 20. 21. REMOVE INTAKE MANIFOLD STAY REMOVE VCV 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark EC−9 EMISSION CONTROL 22. (a) (b) − EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM INSPECT VCV Apply vacuum above 9.3 kPa (70 mmHg, 2.76 in.Hg) to pipe S. Blow air into pipe Y and check that air comes out of pipe Z. (c) (d) Stop the applied vacuum. Blow air into pipe Y and check that air does not come out of pipe Z. If operation is not as specified, replace the VCV. 23. REINSTALL VCV 24. INSTALL INTAKE MANIFOLD STAY Torque: 36 N·m (360 kgf·cm, 26 ft·lbf) 25. 26. REMOVE INTAKE MANIFOLD STAY REMOVE CHECK VALVE 27. (a) INSPECT CHECK VALVE Check that air flows from the orange pipe to the black pipe. (b) Check that air does not flow from the black pipe to the orange pipe. If operation is not as specified, replace the check valve. Orange Pipe Black Pipe EC0107 28. REINSTALL CHECK VALVE HINT: Reinstall the check valve with the black pipe facing the VCV side. 29. INSTALL INTAKE MANIFOLD STAY Torque: 36 N·m (360 kgf·cm, 26 ft·lbf) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark EC−10 EMISSION CONTROL − EXHAUST GAS RECIRCULATION (EGR) SYSTEM EXHAUST GAS RECIRCULATION (EGR) SYSTEM EC0GC−01 COMPONENTS 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 623 Brought to you by BirfMark EC−11 EMISSION CONTROL − EXHAUST GAS RECIRCULATION (EGR) SYSTEM INSPECTION 1. EC0JT−01 INSPECT AND CLEAN FILTER IN EGR VACUUM MODULATOR Remove the cap and filter. Check the filter for contamination or damage. Using compressed air, clean the filter. Reinstall the filter and cap. (a) (b) (c) (d) HINT: Install the filter with the coarser surface facing the atmospheric side (outward). 2. INSTALL VACUUM GAUGE Using a 3−way connector, connect a vacuum gauge to the hose between the EGR valve and EGR vacuum modulator. 3. INSPECT SEATING OF EGR VALVE Start the engine and check that the engine starts and runs at idle. 4. CONNECT TOYOTA HAND−HELD TESTER OR OBD II SCAN TOOL (See page EM−10) 5. INSPECT VSV OPERATION WITH COLD ENGINE (a) The engine coolant temperature should be below 47°C (117°F). (b) Check that the vacuum gauge indicates zero at 2,500 rpm. (c) Check that the EGR pipe is not hot. 6. (a) (b) (c) (d) INSPECT OPERATION OF VSV AND EGR VACUUM MODULATOR WITH HOT ENGINE Warm up the engine to above 53°C (127°F). Check that the vacuum gauge indicates low vacuum at 2,500 rpm. Disconnect the vacuum hose port R of the EGR vacuum modulator and connect port R directly to the air intake chamber with another hose. Check that the vacuum gauge indicates high vacuum at 2,500 rpm. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark EC−12 EMISSION CONTROL − EXHAUST GAS RECIRCULATION (EGR) SYSTEM HINT: As a large amount of exhaust gas enters, the engine will misfire slightly. 7. DISCONNECT TOYOTA HAND−HELD TESTER OR OBD II SCAN TOOL 8. REMOVE VACUUM GAUGE Remove the vacuum gauge, and reconnect the vacuum hoses to the proper locations. 9. (a) INSPECT EGR VALVE Apply vacuum directly to the EGR valve with the engine idle. (b) Check that the engine runs rough or dies. (c) Reconnect the vacuum hoses to the proper locations. If no problem is found with this inspection, system is normal; otherwise inspect each part. 10. CANCEL DIAGNOSTIC TROUBLE CODE 11. REMOVE AIR INTAKE CHAMBER (See page EM−28) 12. DISCONNECT VACUUM HOSES AND CONNECTOR 13. INSPECT VSV FOR OPEN CIRCUIT Using an ohmmeter, check that there is continuity between the terminals. Resistance: 30 − 34 Ω at 20°C (68°F) If there is no continuity, replace the VSV. 14. INSPECT VSV FOR GROUND Using an ohmmeter, check that there is no continuity between each terminal and the body. If there is continuity, replace the VSV. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark EC−13 EMISSION CONTROL 15. (a) − EXHAUST GAS RECIRCULATION (EGR) SYSTEM INSPECT VSV OPERATION Check that the air flows from pipe G to pipe E. (b) Apply battery voltage across the terminals. (c) Check that the air does not flows from pipe G to pipe E. If operation is not as specified, replace the VSV. 16. RECONNECT VACUUM HOSES AND CONNECTOR 17. REINSTALL AIR INTAKE CHAMBER (See page EM−54) 18. (b) (a) (b) (c) (a) DISCONNECT VACUUM HOSES FROM EGR VACUUM MODULATOR Disconnect the vacuum hose from R port. Disconnect the vacuum hose from Q port. Disconnect the vacuum hose from P port. (c) 19. (a) (b) INSPECT EGR VACUUM MODULATOR OPERATION Block ports P and R with your finger. Blow air into port Q, and check that the air passes through to the air filter side freely. (c) Start the engine, and maintain speed at 2,500 rpm. (d) Repeat the above test. Check that there is a strong resistance to air flow. If operation is not as specified, replace the EGR vacuum modulator. 20. (a) (b) (c) RECONNECT VACUUM HOSES TO EGR VACUUM MODULATOR Connect the vacuum hose to R port. Connect the vacuum hose to Q port. Connect the vacuum hose to P port. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark EC−14 EMISSION CONTROL − EXHAUST GAS RECIRCULATION (EGR) SYSTEM 21. REMOVE EGR VACUUM MODULATOR 22. (a) (b) (c) (d) REMOVE EGR VALVE Disconnect the vacuum hose from the EGR valve. Disconnect the engine wire from the clamp. Loosen the EGR pipe union nut. Remove the 2 nuts holding the EGR valve to the air intake chamber. (e) Using 2 nuts, remove the 2 stud bolts, EGR valve and gasket. 23. INSPECT EGR VALVE Check for sticking and heavy carbon deposits. If a problem is found, replace the valve. 24. REINSTALL EGR VALVE (a) Using 2 nuts, temporarily install a new gasket, and EGR valve with the 2 stud bolts. Torque: 9 N·m (90 kgf·cm, 78 in.·lbf) (b) Install the 2 nuts holding the EGR valve to the air intake chamber. Torque: 18 N·m (180 kgf·cm, 13 ft·lbf) (c) Tighten the union nut of the EGR pipe. Torque: 64 N·m (650 kgf·cm, 47 ft·lbf) (d) Connect the engine wire to the clamp. (e) Connect the vacuum hose to the EGR valve. 25. REINSTALL EGR VACUUM MODULATOR Torque: 18 N·m (185 kgf·cm, 13 ft·lbf) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark EMISSION CONTROL − THREE−WAY CATALYTIC CONVERTER (TWC) SYSTEM EC−15 THREE−WAY CATALYTIC CONVERTER (TWC) SYSTEM EC0H3−02 INSPECTION 1. EXHAUST PIPE ASSEMBLY INSPECTION (a) Check connection for looseness or damage (b) Check clamps for weakness, cracks or damage 2. TWC INSPECTION Check for dents or damage If any part of the protector is damaged or dented to the extent that it touches the TWC, repair or replace it. 3. HEAT INSULATOR INSPECTION (a) Check heat insulator for damage (b) Check for adequate clearance between TWC and heat insulator. 4. FRONT TWC AND REAR TWC REPLACEMENT (See page EM−110) 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 628 Brought to you by BirfMark EM−1 ENGINE MECHANICAL − CO/HC CO/HC EM1E0−04 INSPECTION HINT: This check is used only to determine whether or not the idle CO/ HC complies with regulations. 1. INITIAL CONDITIONS (a) Engine at normal operating temperature (b) Air cleaner installed (c) All pipes and hoses of air induction system connected (d) All accessories switched OFF (e) All vacuum lines properly connected HINT: All vacuum hoses for EGR systems, etc. should be properly connected. (f) SFI system wiring connectors fully plugged (g) Ignition timing set correctly (h) Transmission in neutral position (i) Tachometer and CO/HC meter calibrated by hand 2. START ENGINE 3. RACE ENGINE AT 2,500 RPM FOR APPROX. 180 SECONDS 4. 5. 4.INSERT CO/HC METER TESTING PROBE AT LEAST 40 cm (1.3 ft) INTO TAILPIPE DURING IDLING IMMEDIATELY CHECK CO/HC CONCENTRATION AT IDLE AND/OR 2,500 RPM HINT: When doing the 2 mode (2,500 rpm and idle) test, follow the measurement order prescribed by the applicable local regulations. 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 504 Brought to you by BirfMark EM−2 ENGINE MECHANICAL − CO/HC 6. TROUBLESHOOTING If the CO/HC concentration does not comply with regulations, troubleshoot in the order given below. See the table below for possible causes, and then inspect and correct the applicable causes if necessary. CO Normal Low High HC High High High Problems Causes Rough idle 3. Faulty ignitions: S Incorrect timing S Fouled, shorted or improperly gapped plugs S Open or crossed high−tension cords S Cracked distributor cap 4. Incorrect valve clearance 5. Leaky EGR valve 6. Leaky intake and exhaust valves 7. Leaky cylinders Rough idle (Fluctuating HC reading) 1. Vacuum leaks: S PCV hose S EGR valve S Intake manifold S Air intake chamber S Throttle body S IAC valve S Brake booster line 2. Lean mixture causing misfire Rough idle (Black smoke from exhaust) 1. Restricted air filter 2. Faulty SFI systems: S Faulty pressure regulator S Clogged fuel return line S Defective ECT sensor S Faulty ECM S Faulty injector S Faulty throttle position sensor S Faulty MAF meter 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 505 Brought to you by BirfMark EM−3 ENGINE MECHANICAL − COMPRESSION COMPRESSION EM0KR−04 INSPECTION HINT: If there is lack of power, excessive oil consumption or poor fuel economy, measure the compression pressure. 1. WARM UP AND STOP ENGINE Allow the engine to warm up to normal operating temperature. 2. DISCONNECT DISTRIBUTOR CONNECTOR 3. REMOVE SPARK PLUGS (See page IG−1) 4. (a) (b) (c) CHECK CYLINDER COMPRESSION PRESSURE Insert a compression gauge into the spark plug hole. Fully open the throttle. While cranking the engine, measure the compression pressure. HINT: Always use a fully charged battery to obtain engine speed of 250 rpm or more. (d) Repeat steps (a) through (c) for each cylinder. NOTICE: This measurement must be done in as short a time as possible. Compression pressure: 1,176 kPa (12.0 kgf/cm2, 171 psi) or more Minimum pressure: 883 kPa (9.0 kgf/cm2, 128 psi) Difference between each cylinder: 98 kPa (1.0 kgf/cm2, 14 psi) or less If the cylinder compression in one or more cylinders is low, pour a small amount of engine oil into the cylinder through the spark plug hole and repeat steps (a) through (c) for cylinders with low compression. S If adding oil helps the compression, it is likely that the piston rings and/or cylinder bore are worn or damaged. S If pressure stays low, a valve may be sticking or seating is improper, or there may be leakage past the gasket. 5. REINSTALL SPARK PLUGS (See page IG−1) 6. RECONNECT DISTRIBUTOR CONNECTOR 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 506 Brought to you by BirfMark EM−4 ENGINE MECHANICAL − VALVE CLEARANCE VALVE CLEARANCE EM1Q4−01 INSPECTION HINT: Inspect and adjust the valve clearance when the engine is cold. 1. DRAIN ENGINE COOLANT 2. REMOVE THROTTLE BODY (See page SF−45) 3. (a) (b) 4. DISCONNECT ENGINE WIRE AND HEATER VALVE FROM COWL PANEL Remove the 2 bolts and disconnect the ground strap and engine wire. Remove the 2 bolts and disconnect the heater valve. DISCONNECT HIGH−TENSION CORDS FROM SPARK PLUGS (See page IG−1) 5. REMOVE CYLINDER HEAD COVER Remove the 13 bolts, cylinder head cover and gasket. 1 Dot Mark P05120 6. (a) SET NO. 1 CYLINDER TO TDC/COMPRESSION Turn the crankshaft pulley, and align its groove with the timing mark ”0” of the timing chain cover. (b) Check that the timing marks (1 and 2 dots) of the camshaft drive and driven gears are in straight line on the cylinder head surface as shown in the illustration.If not, turn the crankshaft 1 revolution (360°) and align the marks as above. A16078 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 507 Brought to you by BirfMark EM−5 ENGINE MECHANICAL 7. (a) − VALVE CLEARANCE INSPECT VALVE CLEARANCE Check only the valves indicated. S Using a thickness gauge, measure the clearance between the valve lifter and camshaft. S Record the out−of−specification valve clearance measurements. They will be used later to determine the required replacement adjusting shim. Valve clearance (Cold): Intake 0.15 − 0.25 mm (0.006 − 0.010 in.) Exhaust 0.25 − 0.35 mm (0.010 − 0.041 in.) (b) Turn the crankshaft pulley 1 revolution (360°) and align the its groove with timing mark ”0” of the timing chain cover. (c) Check only the valves indicated as shown. Measure the valve clearance (See procedure in step (a) above). 8. Except for rear valves of No. 6 cylinder ADJUST VALVE CLEARANCE Remove the adjusting shim. S Turn the crankshaft to position the cam lobe of the camshaft on the adjusting valve upward. S Position the notch of the valve lifter toward the spark plug side. (a) 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 508 Brought to you by BirfMark EM−6 ENGINE MECHANICAL − VALVE CLEARANCE Using SST (A), press down the valve lifter and place SST (B) between the camshaft and valve lifter flange. Remove SST (A). SST 09248−06020, 09248−55050 (09248−05510) S HINT: S S S (b) EM0494 Apply SST (B) at slight angle on the side marked with ”11”, at the position shown in the illustration. When SST (B) is inserted too deeply, it will get pinched by the shim. To prevent it from being stuck, insert it shallowly from the outside of the cylinder head, at a slight angle. Remove the adjusting shim with a small screwdriver and magnetic finger. Determine the replacement adjusting shim size by following the Formula or Charts: S Using a micrometer, measure the thickness of the removed shim. S Calculate the thickness of a new shim so that the valve clearance comes within specified value. T ....... Thickness of removed shim A ....... Measured valve clearance N ....... Thickness of new shim Intake: N = T + (A − 0.20 mm (0.008 in.)) Exhaust: N = T + (A − 0.30 mm (0.012 in.)) S Select a new shim with a thickness as close as possible to the calculated value. HINT: Shims are available in 17 sized in increments of 0.05 mm (0.0020 in.), from 2.50 mm (0.0984 in.) to 3.30 mm (0.1299 in.). (c) (d) Install a new adjusting shim. S Place a new adjusting shim on the valve lifter. S Using SST (A), press down the valve lifter and remove SST (B). SST 09248−06020, 09248−55050 (09248−05510) Recheck the valve clearance. 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 509 Brought to you by BirfMark EM−7 ENGINE MECHANICAL 9. (a) (b) (c) (d) EM0494 − VALVE CLEARANCE Rear valves of No. 6 cylinder ADJUST VALVE CLEARANCE Remove the distributor (See page IG−10). Remove the camshafts (See page EM−28). Remove the adjusting shim with a small screwdriver. Determine the replacement adjusting shim size by following the Formula or Charts: S Using a micrometer, measure the thickness of the removed shim. S Calculate the thickness of a new shim so that the valve clearance comes within specified value. T ....... Thickness of removed shim A ....... Measured valve clearance N ....... Thickness of new shim Intake: N = T + (A − 0.20 mm (0.008 in.)) Exhaust: N = T + (A − 0.30 mm (0.012 in.)) S Select a new shim with a thickness as close as possible to the calculated value. HINT: Shims are available in 17 sized in increments of 0.05 mm (0.0020 in.), from 2.50 mm (0.0984 in.) to 3.30 mm (0.1299 in.). (e) Place a new adjusting shim on the valve lifters. (f) Install the camshafts (See page EM−54). (g) Recheck the valve clearance. (h) Install the distributor (See page IG−11). 10. REINSTALL CYLINDER HEAD COVER (a) Install the gasket to the cylinder head cover. (b) Install the cylinder head cover with the 13 bolts. 11. RECONNECT HIGH−TENSION CORDS TO SPARK PLUGS (See page IG−1) 12. RECONNECT HEATER VALVE AND ENGINE WIRE TO COWL PANEL (a) Connect the heater valve with the 2 bolts. (b) Connect the ground strap and engine wire with the 2 bolts. 13. REINSTALL THROTTLE BODY (See page SF−48) 14. REFILL RADIATOR WITH ENGINE COOLANT 15. CHECK AND ADJUST IGNITION TIMING (See page EM−10) 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 510 EXAMPLE: The 2.800 mm (0.1102 in.) shim is installed, and the measured clearance is 0.440 mm (0.0173 in.). Replace the 2.800 mm (0.1102 in.) shim with a No. 12 shim. Intake valve clearance (Cold): 0.15 − 0.25 mm (0.006 − 0.010 in.) Adjusting Shim Selection Chart (Intake) Thickness Thickness − Brought to you by BirfMark Version 1.11 - 03/16/2010 Author: Shim No. mm (in.) ENGINE MECHANICAL HINT: New shims have the thickness in millimeter imprinted on the face Shim No. New shim thickness Brought to you by BirfMark EM−8 VALVE CLEARANCE V00831 1996 LAND CRUISER (RM451U) Date: 511 Measured clearance mm (in.) Installed shim thickness mm (in.) EXAMPLE: The 2.800 mm (0.1102 in.) shim is installed, and the measured clearance is 0.440 mm (0.0173 in.). Replace the 2.800 mm (0.1102 in.) shim with a No. 10 shim. Exhaust valve clearance (Cold): 0.25 − 0.35 mm (0.010 − 0.014 in.) Adjusting Shim Selection Chart (Exhaust) Thickness Brought to you by BirfMark Version 1.11 - 03/16/2010 Author: Thickness − Shim No. mm (in.) ENGINE MECHANICAL HINT: New shims have the thickness in millimeter imprinted on the face Shim No. New shim thickness Brought to you by BirfMark VALVE CLEARANCE EM−9 V00832 1996 LAND CRUISER (RM451U) Date: 512 Brought to you by BirfMark EM−10 ENGINE MECHANICAL − IGNITION TIMING IGNITION TIMING EM0KT−06 INSPECTION 1. WARM UP ENGINE Allow the engine to warm up to normal operating temperature. 2. CONNECT TOYOTA HAND−HELD TESTER OR OBD II SCAN TOOL (a) Remove the fuse cover on the instrument panel. (b) (c) 3. 4. (a) (b) 5. (a) (b) (c) (d) (e) 6. Connect the TOYOTA hand−held tester or OBD II scan tool to the DLC3. Please refer to the TOYOTA hand−held tester or OBD II scan tool operator’s manual for further details. CONNECT TIMING LIGHT TO ENGINE CHECK IDLE SPEED Race the engine speed at 2,500 rpm for approx. 90 seconds. Check the idle speed. Idle speed: 650 ± 50 rpm INSPECT AND ADJUST IGNITION TIMING Using SST, connect terminals TE1 and E1 of the DLC1. SST 09843−18020 Using a timing light, check the ignition timing. Ignition timing: 3° BTDC @ idle (Transmission in neutral position and A/C OFF) Loosen the hold−down bolt, and adjust by turning the distributor. Tighten the hold−down bolt, and recheck the ignition timing. Torque: 18 N·m (180 kgf·cm, 13 ft·lbf) Remove the SST from the DLC1. SST 09843−18020 FURTHER CHECK IGNITION TIMING Ignition timing: 2 − 13° BTDC @ idle (Transmission in neutral position and A/C OFF) HINT: The timing mark moves in a range between 2° and 13°. 7. DISCONNECT TIMING LIGHT FROM ENGINE 8. DISCONNECT TOYOTA HAND−HELD TESTER OR OBD II SCAN TOOL 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 513 Brought to you by BirfMark EM−11 ENGINE MECHANICAL − IDLE SPEED IDLE SPEED EM0KU−05 INSPECTION 1. INITIAL CONDITIONS (a) Engine at normal operating temperature. (b) Air cleaner installed. (c) All pipes and hoses of air induction system connected. (d) All accessories switched OFF. (e) All vacuum lines properly connected. HINT: All vacuum hoses for EGR system, etc. should be properly connected. (f) SFI system wiring connectors fully plugged. (g) Ignition timing set correctly. (h) Transmission in neutral position. (i) Air conditioning switched OFF. 2. CONNECT TOYOTA HAND−HELD TESTER OR OBD II SCAN TOOL (See page EM−10) 3. INSPECT IDLE SPEED (a) Race the engine speed at 2,500 rpm for approx. 90 seconds. (b) Check the idle speed. Idle speed: 650 ± 50 rpm If the idle speed is not as specified, check the IAC valve. 4. DISCONNECT TOYOTA HAND−HELD TESTER OR OBD II SCAN TOOL 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 514 Brought to you by BirfMark EM−12 ENGINE MECHANICAL − TIMING CHAIN TIMING CHAIN EM1E8−01 COMPONENTS 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 515 Brought to you by BirfMark EM−13 ENGINE MECHANICAL − TIMING CHAIN REMOVAL EM1E9−01 1. 2. 3. 4. DRAIN ENGINE OIL DRAIN ENGINE COOLANT REMOVE ENGINE UNDER COVER REMOVE RADIATOR (See page CO−14) 5. (a) DISCONNECT A/C COMPRESSOR AND BRACKET Loosen the idler pulley nut and adjusting bolt, and remove the drive belt. Remove the 4 mounting bolts, and disconnect the compressor from the bracket. (b) HINT: Put aside the compressor, and suspend it. (c) Remove the 5 bolts and A/C compressor bracket. 6. (a) (b) REMOVE RADIATOR PIPE Disconnect the No. 2 radiator hose from the water inlet. Remove the 2 nuts and radiator pipe. 7. REMOVE WATER PUMP Remove the 4 bolts, 2 nuts, water pump and gasket. 8. REMOVE CYLINDER HEAD (See page EM−28) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark EM−14 ENGINE MECHANICAL − TIMING CHAIN 9. DISCONNECT OIL COOLER PIPE BRACKET FROM NO. 1 OIL PAN 10. (a) (b) REMOVE OIL LEVEL SENSOR Remove the 4 bolts and level sensor. Remove the gasket from the level sensor. 11. REMOVE BOLTS HOLDING NO.1 OIL PAN TO TRANSMISSION HOUSING Remove the 6 bolts. 12. REMOVE NO. 2 OIL PAN (See page LU−5) 13. REMOVE NO. 1 OIL PAN (See page LU−5) 14. (a) (b) REMOVE CRANKSHAFT PULLEY Using SST, remove the pulley bolt. SST 09213−58012, 09330−00021 Remove the crankshaft pulley. HINT: If necessary, remove the pulley with SST. SST 09950−50010 (09951−05010, 09952−05010, 09953−05010, 09953−05020, 09954−05020) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark EM−15 ENGINE MECHANICAL − TIMING CHAIN 15. CHECK THRUST CLEARANCE OF OIL PUMP DRIVE SHAFT GEAR Using a dial indicator with lever type attachment, measure the thrust clearance. Standard thrust clearance: 0.040 − 0.160 mm (0.0016 − 0.0063 in.) Maximum thrust clearance: 0.30 mm (0.0118 in.) If the thrust clearance is greater than maximum, replace the oil pump drive shaft gear and/or timing chain cover. 16. REMOVE DRIVE BELT IDLER PULLEY Remove the bolt and idler pulley. 17. (a) REMOVE TIMING CHAIN COVER Remove the 9 mounting bolts, 2 mounting nuts and drive belt adjusting bar. (b) Remove the oil pump by prying the portions between the cylinder block and oil pump with a screwdriver. NOTICE: Be careful not to damage the contact surfaces of the cylinder block and oil pump. (c) Remove the O−rings from the oil pump. (d) Remove the gasket from the oil pump. 18. REMOVE TIMING CHAIN AND CAMSHAFT TIMING GEAR 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark EM−16 ENGINE MECHANICAL − TIMING CHAIN 19. REMOVE CRANKSHAFT TIMING GEAR HINT: If necessary, remove the gear with SST. SST 09950−40010 (09951−04010, 09952−04010, 09953−04020, 09954−04010, 09955−04060), 09950−60010 (09951−00350) 20. (a) (b) REMOVE CHAIN TENSIONER SLIPPER AND VIBRATION DAMPER Using a 10 mm hexagon wrench, remove the bolt and slipper. Remove the 2 bolts and damper. 21. REMOVE OIL JET Remove the bolt and oil jet. 22. REMOVE CRANKSHAFT ROTOR 23. REMOVE OIL PUMP DRIVE SHAFT GEAR 24. REMOVE PUMP DRIVE SHAFT GEAR If the pump drive shaft gear cannot be removed by hand, use 2 screwdrivers. NOTICE: Position shop rags as shown to prevent damage. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark EM−17 ENGINE MECHANICAL − TIMING CHAIN EM1EA−01 INSPECTION 1. (a) 146.6 mm 16 Links P04776 INSPECT TIMING CHAIN AND TIMING GEARS Measure the length of 16 links with the chain fully stretched. Maximum chain elongation: 146.6 mm (5.772 in.) If the elongation is greater than maximum, replace the chain. HINT: Make the same measurements pulling at 3 or more places selected at random. (b) (c) Wrap the chain around the timing gear. Using vernier calipers, measure the timing gear diameter with the chain. NOTICE: Vernier calipers must contact the chain rollers for measuring. Minimum gear diameter (w/Chain): P03876 Camshaft 126.0 mm (4.961 in.) Crankshaft 65.4 mm (2.575 in.) If the diameter is less than minimum, replace the chain and gears. 2. INSPECT CHAIN TENSIONER SLIPPER AND VIBRATION DAMPER Measure the chain tensioner slipper and vibration damper wears. Maximum wear: 1.0 mm (0.039 in.) If the wear is greater than maximum, replace the slipper and/or damper. 3. INSPECT OIL JET Check the oil jet for damage or clogging. If necessary, replace the oil jet. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark EM−18 ENGINE MECHANICAL − TIMING CHAIN EM1Q5−01 REPLACEMENT REPLACE CRANKSHAFT FRONT OIL SEAL (See page EM−99) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark EM−19 ENGINE MECHANICAL − TIMING CHAIN INSTALLATION EM1EB−01 1. SET CRANKSHAFT Turn the crankshaft until the set key on crankshaft facing downward. 2. INSTALL PUMP DRIVE SHAFT GEAR 3. (a) INSTALL OIL PUMP DRIVE SHAFT GEAR Apply a light coat of engine oil on the shaft portion of the gear. Install the gear. (b) 4. INSTALL CRANKSHAFT ROTOR 5. INSTALL OIL JET Install the oil jet with the bolt. Torque: 20 N·m (200 kgf·cm, 14 ft·lbf) 6. (a) (b) INSTALL CHAIN TENSIONER SLIPPER AND VIBRATION DAMPER Install the damper with the 2 bolts. Torque: 20 N·m (200 kgf·cm, 14 ft·lbf) Using a 10 mm hexagon wrench, install the slipper with the bolt. Torque: 69 N·m (700 kgf·cm, 51 ft·lbf) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark EM−20 ENGINE MECHANICAL (c) − TIMING CHAIN Check that the slipper moves smoothly. 7. INSTALL CRANKSHAFT TIMING GEAR NOTICE: Be careful of the installation direction. HINT: If necessary, install the gear with SST. SST 09636−20010 8. (a) (b) INSTALL TIMING CHAIN AND CAMSHAFT TIMING GEAR Install the timing chain on the camshaft timing gear with the bright link aligned with the timing mark on the camshaft timing gear. Install the timing chain on the crankshaft timing gear with the other bright link aligned with the timing mark on the crankshaft timing gear. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark EM−21 ENGINE MECHANICAL (c) 9. (a) (b) − TIMING CHAIN Tie the timing chain with a cord as shown in the illustration and make sure it doesn’t come loose. INSTALL TIMING CHAIN COVER Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the timing chain cover and cylinder block. S Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and sealing grooves. S Thoroughly clean all components to remove all the loose material. S Using a non−residue solvent, clean both sealing surfaces. Apply seal packing to the timing chain cover as shown in the illustration. Seal packing: Part No. 08826−00080 or equivalent S Install a nozzle that has been cut to a 2 − 3 mm (0.08 − 0.12 in.) opening. HINT: Avoid applying an excessive amount to the surface. S Parts must be assembled within 5 minutes of application. Otherwise the material must be removed and reapplied. S Immediately remove nozzle from the tube and reinstall cap. (c) Place 2 new O−rings in position on the timing chain cover. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark EM−22 ENGINE MECHANICAL − TIMING CHAIN (d) Engage the gear of the oil pump drive rotor with the gear of the oil pump drive gear, and install the oil pump. (e) Install the oil pump and drive belt adjusting bar with the 9 bolts and 2 nuts. Torque: 21 N·m (210 kgf·cm, 15 ft·lbf) HINT: Each bolt length is indicated in the illustration. Bolt A: 30 mm (1.18 in.) Bolt B: 50 mm (1.97 in.) Bolt C: 60 mm (2.38 in.) (f) Remove the cord from the chain. 10. INSTALL DRIVE BELT IDLER PULLEY Install the pulley with the bolt. Torque: 43 N·m (440 kgf·cm, 32 ft·lbf) 11. (a) INSTALL CRANKSHAFT PULLEY Align the pulley set key with the key groove of the pulley, and slide on the pulley. (b) Using SST, install and torque the pulley bolt. SST 09213−58012, 09330−00021 Torque: 412 N·m (4,200 kgf·cm, 304 ft·lbf) 12. INSTALL NO. 1 OIL PAN (See page LU−12) 13. INSTALL NO. 2 OIL PAN (See page LU−12) 14. INSTALL BOLTS HOLDING NO. 1 OIL PAN TO TRANSMISSION HOUSING Install the 6 bolts. Torque: 72 N·m (730 kgf·cm, 53 ft·lbf) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark EM−23 ENGINE MECHANICAL 15. (a) (b) 16. − TIMING CHAIN INSTALL OIL LEVEL SENSOR Install a new gasket to the level sensor. Install the level sensor with the 4 bolts. Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf) CONNECT OIL COOLER PIPE BRACKET TO NO. 1 OIL PAN 17. INSTALL CYLINDER HEAD (See page EM−54) NOTICE: However, for the installation of the camshaft timing gear and timing chain, follow the below procedure. Align the blight link of the timing chain and camshaft timing gear mark, and install them to the camshaft. 18. INSTALL WATER PUMP Install a new gasket and water pump with the 4 bolts and 2 nuts. Torque: 21 N·m (210 kgf·cm, 15 ft·lbf) 19. INSTALL RADIATOR PIPE (a) Connect the No.2 radiator hose to the water inlet. (b) Install the 2 nuts holding the radiator pipe to the No.1 oil pan. Torque: 21 N·m (210 kgf·cm, 15 ft·lbf) 20. INSTALL A/C COMPRESSOR AND BRACKET (a) Install the A/C compressor bracket with the 5 bolts. Torque: 37 N·m (375 kgf·cm, 27 ft·lbf) (b) Install the A/C compressor with the 4 bolts. Torque: 25 N·m (250 kgf·cm, 18 ft·lbf) (c) Install and adjust the drive belt (See page CH−2). 21. INSTALL RADIATOR (See page CO−16) 22. FILL ENGINE WITH OIL 23. INSTALL ENGINE UNDER COVER 24. START ENGINE AND CHECK FOR LEAKS 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark EM−24 ENGINE MECHANICAL − CYLINDER HEAD CYLINDER HEAD EM1E2−01 COMPONENTS 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 527 Brought to you by BirfMark EM−25 ENGINE MECHANICAL − CYLINDER HEAD 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 528 Brought to you by BirfMark EM−26 ENGINE MECHANICAL − CYLINDER HEAD 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 529 Brought to you by BirfMark EM−27 ENGINE MECHANICAL − CYLINDER HEAD 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 530 Brought to you by BirfMark EM−28 ENGINE MECHANICAL − CYLINDER HEAD REMOVAL 1. 2. (a) (b) (c) (d) 3. 4. 5. 6. 7. (a) (b) 8. 9. 10. 11. 12. EM1E3−01 DRAIN ENGINE COOLANT REMOVE BATTERY AND BATTERY TRAY Disconnect the battery cables. Remove the nuts, hold−down clamp and battery. Remove the bolt and disconnect the ground strap. Remove the 5 bolts and battery tray. REMOVE AIR CLEANER HOSE AND CAP DISCONNECT CRUISE CONTROL ACTUATOR CABLE FROM THROTTLE BODY DISCONNECT ACCELERATOR CABLE FROM THROTTLE BODY DISCONNECT THROTTLE CABLE FROM THROTTLE BODY DISCONNECT ENGINE GROUND STRAPS Disconnect the ground strap from the No. 1 engine hanger. Disconnect the ground strap from the air intake chamber. DISCONNECT CONNECTOR ON INTAKE MANIFOLD FROM LH FENDER APRON DISCONNECT DISCONNECT DISCONNECT DISCONNECT 13. BRAKE BOOSTER VACUUM HOSE EVAP HOSE FUEL RETURN HOSE HEATER HOSES DISCONNECT ENGINE WIRE AND HEATER VALVE FROM COWL PANEL (a) Remove the 2 bolts and disconnect the engine wire and ground strap. (b) Remove the 2 bolts and disconnect the heater valve. 14. REMOVE NO. 2 AND NO. 3 CYLINDER HEAD COVERS Remove the 4 bolts and head covers. 15. REMOVE DISTRIBUTOR (See page IG−10) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark EM−29 ENGINE MECHANICAL − CYLINDER HEAD 16. DISCONNECT PS RESERVOIR TANK Remove the 3 bolts and disconnect the reservoir tank. 17. 18. 19. 20. DISCONNECT RADIATOR INLET HOSE DISCONNECT NO. 3 WATER BYPASS HOSE REMOVE GENERATOR (See page CH−8) REMOVE THROTTLE BODY (See page SF−45) 21. REMOVE OIL DIPSTICKS AND GUIDES FOR ENGINE AND TRANSMISSION (a) Remove the 2 mounting bolts. (b) Pull out the dipstick together with dipstick guide. (c) Remove the O−ring from the dipstick guide. 22. REMOVE INTAKE MANIFOLD STAY Remove the 2 bolts and intake manifold stay. 23. DISCONNECT FUEL INLET HOSE Remove the union bolt and 2 gaskets, and disconnect the fuel inlet hose from the fuel filter. 24. DISCONNECT ENGINE WIRE (a) Disconnect the connectors. (1) Disconnect the ECT sender gauge connector. (2) Disconnect the ECT cut switch connector. (3) Disconnect the ECT sensor connector. (4) Disconnect the knock sensor connector. (5) Disconnect the crankshaft position sensor connector. (6) Remove the bolt and disconnect the engine wire from the cylinder block. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark EM−30 ENGINE MECHANICAL (b) (c) (d) (e) (f) (g) (h) (i) (j) (k) (l) (m) − CYLINDER HEAD Disconnect the connectors. (1) Disconnect the knock sensor connector. (2) Disconnect the oil level sensor connector. (3) Disconnect the 2 connectors from the transmission. (4) Disconnect the starter connector. Disconnect the 2 heated oxygen sensor connectors. Disconnect the PNP switch connector. Remove the 2 bolts and disconnect the engine wire from the intake manifold and cylinder block. Disconnect the PCV hose from the PCV valve. Remove the bolt holding the engine wire to the intake manifold. Disconnect the connectors. (1) Disconnect the connector for the emission control valve set assembly. (2) Disconnect the 3 injector connectors. Disconnect the engine wire clamp. Disconnect the engine wire clamp. Disconnect the connectors. (1) Disconnect the 3 injector connectors. (2) Disconnect the EGR gas temp. sensor connector. Disconnect the clamp of the No. 6 injector wire from the bracket. Disconnect the engine wire from the cylinder head and intake manifold. 25. DISCONNECT NO. 2 WATER BYPASS PIPE Remove the 3 bolts, and disconnect the bypass pipe from the cylinder head. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark EM−31 ENGINE MECHANICAL 26. (a) (b) (c) (d) (e) (f) 27. (a) (b) − CYLINDER HEAD REMOVE FRONT EXHAUST PIPE Disconnect the heated oxygen sensor connector. Remove the 2 nuts and 2 bolts holding the front exhaust pipe to the rear TWC. Disconnect the front exhaust pipe, and remove the gasket. Loosen the clamp bolt and disconnect the clamp from the No. 1 support bracket. Remove the 2 bolts and No. 1 support bracket. Remove the 4 nuts, front exhaust pipe and 2 gaskets. REMOVE NO. 1 AND NO. 2 EXHAUST MANIFOLDS Remove the 6 bolts, No. 1 heat insulator and No. 2 heat insulator. Remove the 13 nuts, No. 1 exhaust manifold, No. 2 exhaust manifold and 2 gaskets. 28. REMOVE HEATER PIPE Remove the 2 bolts, 2 nuts, ground cable, heater pipe and gasket. 29. (a) (b) REMOVE WATER BYPASS OUTLET AND PIPE Remove the 2 bolts and water bypass outlet and pipe. Remove the 3 O−rings from the water bypass outlet and pipe. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark EM−32 ENGINE MECHANICAL − CYLINDER HEAD 30. REMOVE CYLINDER HEAD COVER Remove the 13 bolts, cylinder head cover and gasket. 31. REMOVE SPARK PLUGS 32. (a) (b) Check that the timing marks (1 and 2 dots) of the camshaft drive and driven gears are in straight line on the cylinder head surface as shown in the illustration. If not, turn the crankshaft 1 revolution (360°) and align the marks as above. 33. REMOVE CHAIN TENSIONER Remove the 2 nuts, chain tensioner and gasket. 1 Dot Mark P08374 SET NO. 1 CYLINDER TO TDC/COMPRESSION Turn the crankshaft pulley and align its groove with the ”0” mark on the timing chain cover. A16075 34. (a) (b) REMOVE CAMSHAFT TIMING GEAR Remove the semi−circular plug. Place the matchmarks on the camshaft timing gear and timing chain. (c) Hold the intake camshaft with a wrench, remove the bolt and distributor gear. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark EM−33 ENGINE MECHANICAL − CYLINDER HEAD (d) Remove the camshaft timing gear and chain from the intake camshaft and leave on the slipper and damper. 35. REMOVE CAMSHAFTS NOTICE: Since the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being removed. If the camshaft is not kept level, the portion of the cylinder head receiving the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, the following steps should be carried out. (a) Remove the exhaust camshaft. (1) Bring the service bolt hole of the driven sub−gear upward by turning the hexagon wrench head portion of the exhaust camshaft with a wrench. (2) Secure the exhaust camshaft sub−gear to the main gear with a service bolt. Recommended service bolt: Thread diameter 6 mm Thread pitch 1.0 mm Bolt length 16 − 20 mm (0.63 − 0.79 in.) HINT: When removing the camshaft, make sure that the torsional spring force of the sub−gear has been eliminated by the above operation. 2 Dot Marks P22143 (3) Set the timing mark (2 dot marks) of the camshaft driven gear at approx. 35° angle by turning the hexagon wrench head portion of the intake camshaft with a wrench. (4) Lightly push the camshaft towards the rear without applying excessive force. Loosen and remove the No. 1 bearing cap bolts, alternately loosening the left and right bolts uniformly. A16076 (5) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark EM−34 ENGINE MECHANICAL (6) − CYLINDER HEAD Loosen and remove the No. 2, No. 3, No. 5 and No. 7 bearing cap bolts, alternately loosening the left and right bolts uniformly in several passes, in the sequence shown. NOTICE: Do not remove the No. 4 and No. 6 bearing cap bolts at this stage. (7) Remove the 4 bearing caps. (8) Alternately and uniformly loosen and remove the No. 4 and No. 6 bearing cap bolts. HINT: As the 4 No. 4 and No. 6 bearing cap bolts are loosened, make sure that the camshaft is lifted out straight and level. S If the camshaft is not being lifted out straight and level, retighten the 4 No. 4 and No. 6 bearing cap bolts. Then reverse the order of above steps from (g) to (e) and repeat steps from (c) to (h) once again. NOTICE: Do not pry on or attempt to force the camshaft with a tool or other object. (9) Remove the 2 bearing caps and exhaust camshaft. S (b) 2 Dot Marks Remove the intake camshaft. (1) Set the timing mark (2 dot marks) of the camshaft drive gear at approx. 25° angle by turning the hexagon wrench head portion of the intake camshaft with a wrench. HINT: The above angle arrows the No. 1 and No. 4 cylinder cam lobes of the intake camshaft to push their valve lifters evenly. P22567 A16077 (2) (3) Lightly push the intake camshaft towards the front without applying excessive force. Loosen and remove the No. 1 bearing cap bolts, alternately loosening the left and right bolts uniformly. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark EM−35 ENGINE MECHANICAL − (4) CYLINDER HEAD Loosen and remove the No. 3, No. 4, No. 6 and No. 7 bearing cap bolts, alternately loosening the left and right bolts uniformly in several passes, in the sequence shown. NOTICE: Do not remove the No. 2 and No. 5 bearing cap bolts at this stage. (5) Remove the 4 bearing caps. (6) Alternately and uniformly loosen and remove the No. 2 and No. 5 bearing cap bolts. HINT: As the 4 No. 2 and No. 5 bearing cap bolts are loosened, make sure that the camshaft is lifted out straight and level. S If the camshaft is not being lifted out straight and level, retighten the 4 No. 2 and No. 5 bearing cap bolts. Then reverse the order of above steps from (e) to (c) and repeat steps from (a) to (f) once again. NOTICE: Do not pry on or attempt to force the camshaft with a tool or other object. (7) Remove the 2 bearing caps and exhaust camshaft. S 36. (a) DISASSEMBLE EXHAUST CAMSHAFT Mount the hexagon wrench head portion of the camshaft in a vise. NOTICE: Be careful not to damage the camshaft. (b) Insert a service bolt (A) into the service hole of the camshaft sub−gear. (c) Using a screwdriver, turn the sub−gear clockwise, and remove the service bolt (B). NOTICE: Be careful not to damage the camshaft. (d) Using snap ring pliers, remove the snap ring. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark EM−36 ENGINE MECHANICAL − CYLINDER HEAD (e) Remove the wave washer (1), camshaft sub−gear (2) and camshaft gear spring (3). 37. REMOVE CYLINDER HEAD AND INTAKE MANIFOLD ASSEMBLY Remove the 2 bolts in front of the head before the other head bolts are removed. (a) (b) Uniformly loosen and remove the 14 cylinder head bolts, in several passes, in the sequence shown. NOTICE: Cylinder head warpage or cracking could result from removing bolts in incorrect order. (c) Lift the cylinder head from the dowels on the cylinder block, and place the cylinder head on wooden blocks on a bench. HINT: If the cylinder head is difficult to lift off, pry between the cylinder head and cylinder block with a screwdriver. NOTICE: Be careful not to damage the contact surfaces of the cylinder head and cylinder block. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark EM−37 ENGINE MECHANICAL − CYLINDER HEAD DISASSEMBLY EM1E4−01 1. REMOVE GENERATOR BRACKET Remove the 2 bolts and generator bracket. 2. REMOVE WATER OUTLET Remove the 2 nuts, water outlet and gasket. 3. (a) (b) REMOVE EGR PIPE Loosen the union nut. Remove the 2 bolts, EGR pipe and gasket. 4. REMOVE HEATER INLET PIPE AND HOSE Remove the 2 bolts, and disconnect the pipe and hose. 5. (a) (b) 6. (a) (b) 7. REMOVE AIR INTAKE CHAMBER AND INTAKE MANIFOLD ASSEMBLY Disconnect the 2 vacuum hoses from the TVV. Remove the 10 bolts, 2 nuts, intake manifold and gasket. DISASSEMBLE AIR INTAKE CHAMBER AND INTAKE MANIFOLD ASSEMBLY Disconnect the vacuum sensing hose from the fuel pressure regulator. Remove the 6 bolts, 2 nuts, air intake chamber and 2 gaskets from the intake manifold. REMOVE NO. 1 WATER BYPASS HOSE 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark EM−38 ENGINE MECHANICAL 8. − CYLINDER HEAD REMOVE NO. 1 AND NO. 2 ENGINE HANGERS 9. REMOVE 2 ENGINE WIRE CLAMP BRACKETS Remove the 2 bolts and 2 wire clamp brackets. 10. REMOVE ACCELERATOR CABLE BRACKET AND THROTTLE CABLE BRACKET Remove the 2 bolts and 2 cable brackets. 11. REMOVE VALVE LIFTERS AND SHIMS HINT: Arrange the valve lifters and shims in correct order. 12. (a) (b) REMOVE VALVES Using SST, compress the valve spring and remove the 2 keepers. SST 09202−70020 (09202−00010) Remove the spring retainer, valve spring and valve. (c) Using needle−nose pliers, remove the oil seal. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark EM−39 ENGINE MECHANICAL (d) − CYLINDER HEAD Using compressed air and a magnetic finger, remove the spring seat by blowing air. HINT: Arrange the valves, valve springs, spring seats and spring retainers in correct order. 13. 14. 15. 16. REMOVE ECT SENDER GAUGE REMOVE ECT CUT SWITCH REMOVE ECT SENSOR REMOVE TVV 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark EM−40 ENGINE MECHANICAL − CYLINDER HEAD INSPECTION 1. (a) EM1Q7−01 CLEAN TOP SURFACES OF PISTONS AND CYLINDER BLOCK Turn the crankshaft, and bring each piston to top dead center (TDC). Using a gasket scraper, remove all the carbon from the piston top surface. (b) Using a gasket scraper, remove all the gasket material from the cylinder block surface. (c) Using compressed air, blow carbon and oil from the bolt holes. CAUTION: Protect your eyes when using high−compressed air. 2. (a) CLEAN CYLINDER HEAD Using a gasket scraper, remove all the gasket material from the cylinder block contact surface. NOTICE: Be careful not to scratch the cylinder block contact surface. (b) Using a wire brush, remove all the carbon from the combustion chambers. NOTICE: Be careful not to scratch the cylinder block contact surface. (c) Using a valve guide bushing brush and solvent, clean all the guide bushings. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark EM−41 ENGINE MECHANICAL − CYLINDER HEAD (d) Using a soft brush and solvent, thoroughly clean the cylinder head. 3. (a) INSPECT CYLINDER HEAD Inspect for flatness. Using a precision straight edge and thickness gauge, measure the surfaces contacting the cylinder block and the manifolds for warpage. Maximum warpage: Cylinder block side 0.15 mm (0.0059 in) Manifold side 0.10 mm (0.0039 in) If warpage is greater than maximum, replace the cylinder head. (b) Inspect for cracks. Using a dye penetrant, check the combustion chambers, intake ports, exhaust ports and cylinder block surface for cracks. If cracked, replace the cylinder head. 4. (a) (b) CLEAN VALVES Using a gasket scraper, chip off any carbon from the valve head. Using a wire brush, thoroughly clean the valve. EM0580 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark EM−42 ENGINE MECHANICAL − CYLINDER HEAD 5. (a) INSPECT VALVE STEMS AND GUIDE BUSHINGS Using a caliper gauge, measure the inside diameter of the guide bushing. Bushing inside diameter: 7.010 − 7.030 mm (0.2760 − 0.2768 in.) (b) Using a micrometer, measure the diameter of the valve stem. Valve stem diameter: (c) Intake 6.970 − 6.985 mm (0.2744 − 0.2750 in.) Exhaust 6.965 − 6.980 mm (0.2742 − 0.2748 in.) Subtract the valve stem diameter measurement from the guide bushing inside diameter measurement. Standard oil clearance: Intake 0.025 − 0.060 mm (0.0010 − 0.0024 in.) Exhaust 0.030 − 0.065 mm (0.0012 − 0.0026 in.) Maximum oil clearance: Intake 0.08 mm (0.0031 in.) Exhaust 0.10 mm (0.0039 in.) If the clearance is greater than maximum, replace the valve and guide bushing (See page EM−49). 6. (a) (b) INSPECT AND GRIND VALVES Grind the valve enough to remove pits and carbon. Check that the valve is ground to the correct valve face angle. Valve face angle: 44.5° (c) Check the valve head margin thickness. Margin thickness: 44.5° Z00054 Standard 1.2 mm (0.047 in.) Minimum 1.0 mm (0.039 in.) If the margin thickness is less than minimum, replace the valve. Margin Thickness EM0181 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark EM−43 ENGINE MECHANICAL (d) Overall Length − CYLINDER HEAD Check the valve overall length. Standard overall length: Intake 98.4 mm (3.874 in.) Exhaust 97.4 mm (3.854 in.) Minimum overall length: P03849 Intake 97.9 mm (3.854 in.) Exhaust 97.4 mm (3.835 in.) If the overall length is less than minimum, replace the valve. (e) Check the surface of the valve stem tip for wear. If the valve stem tip is worn, resurface the tip with a grinder or replace the valve. NOTICE: Do not grind off more than minimum. EM0255 7. (a) (b) (c) P04415 INSPECT AND CLEAN VALVE SEATS Using a 45° carbide cutter, resurface the valve seats. Remove only enough metal to clean the seats. Check the valve seating position. Apply a light coat of prussian blue (or white lead) to the valve face. Lightly press the valve against the seat. Do not rotate valve. Check the valve face and seat for the following: S If blue appears 360° around the face, the valve is concentric. If not, replace the valve. S If blue appears 360° around the valve seat, the guide and face are concentric. If not, resurface the seat. S Check that the seat contact is in the middle of the valve face with these width: Intake 1.2 − 1.6 mm (0.047 − 0.063 in.) Exhaust 1.0 − 1.4 mm (0.039 − 0.055 in.) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark EM−44 ENGINE MECHANICAL − CYLINDER HEAD If not, correct the valve seats as follows: (1) Intake: If the seating is too high on the valve face, use 30° and 45° cutters to correct the seat. (2) (d) (e) If the seating is too low on the valve face, use 75° and 45° cutters to correct the seat. Hand−lap the valve and valve seat with an abrasive compound. After hand−lapping, clean the valve and valve seat. 8. (a) INSPECT VALVE SPRINGS Using a steel square, measure the deviation of the valve spring. Maximum deviation: 2.0 mm (0.079 in.) If the deviation is greater than maximum, replace the valve spring. Deviation EM0988 (b) Using vernier calipers, measure the free length of the valve spring. Free length: 43.94 − 45.06 mm (1.7299 − 1.7740 in.) If the free length is not as specified, replace the valve spring. EM0801 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark EM−45 ENGINE MECHANICAL − CYLINDER HEAD (c) Using a spring tester, measure the tension of the valve spring at the specified installed length. Installed tension: 214 − 238 N (21.8 − 24.2 kgf, 48.1 − 53.4 lbf) at 36.5 mm (1.437 in.) If the installed tension is not as specified, replace the valve spring. EM0281 9. (a) INSPECT CAMSHAFTS Inspect for runout. (1) Place the camshaft on V−blocks. (2) Using a dial indicator, measure the circle runout at the center journal. Maximum circle runout: 0.06 mm (0.0024 in.) If the circle runout is greater than maximum, replace the camshaft. (b) Inspect the cam lobes. Using a micrometer, measure the cam lobe height. Standard cam lobe height: 50.61 − 50.71 mm (1.9925 − 1.9965 in.) Minimum cam lobe height: 50.51 mm (1.9886 in.) If the cam lobe height is less than minimum, replace the camshaft. P03976 (c) Inspect the journals. Using a micrometer, measure the journal diameter. Journal diameter: 26.959 − 26.975 mm (1.0614 − 1.0620 in.) If the journal diameter is not as specified, check the oil clearance. P03977 (d) Inspect the camshaft bearings. Check that bearings for flaking and scoring. If the bearings are damaged, replace the bearing caps and cylinder head as a set. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark EM−46 ENGINE MECHANICAL − CYLINDER HEAD (e) Inspect the gear spring Using vernier calipers, measure the free distance between the spring ends. Free distance: 18.2 − 18.8 mm (0.717 − 0.740 in.) If the free distance is not as specified, replace the gear spring. EM3322 (f) Inspect the journal oil clearance. (1) Clean the bearing caps and camshaft journals. (2) Place the camshafts on the cylinder head. (3) Lay a strip of Plastigage across each of the camshaft journals. (4) Install the bearing caps (See page EM−54). NOTICE: Do not turn the camshaft. (5) Remove the bearing caps. (6) Measure the Plastigage at its widest point. Standard oil clearance: 0.025 − 0.062 mm (0.0010 − 0.0024 in.) Maximum oil clearance: 0.10 mm (0.0039 in.) If the oil clearance is greater than maximum, replace the camshaft. If necessary, replace the bearing caps and cylinder head as a set. (7) Completely remove the Plastigage. (g) Inspect the thrust clearance. (1) Install the camshaft (See page EM−54). (2) Using a dial indicator, measure the thrust clearance while moving the camshaft back and forth. Standard thrust clearance: 0.030 − 0.080 mm (0.0012 − 0.0031 in.) Maximum thrust clearance: 0.10 mm (0.0039 in.) If the thrust clearance is greater than maximum, replace the camshaft. If necessary, replace the bearing caps and cylinder head as a set. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark EM−47 ENGINE MECHANICAL − CYLINDER HEAD (h) Inspect the gear backlash. (1) Install the camshafts without installing the exhaust cam sub−gear (See page EM−54). (2) Using a dial indicator, measure the backlash. Standard backlash: 0.020 − 0.200 mm (0.0008 − 0.0079 in.) Maximum backlash: 0.30 mm (0.0188 in.) If the backlash is greater than maximum, replace the camshafts. 10. (a) INSPECT VALVE LIFTER OIL CLEARANCE Using a caliper gauge, measure the lifter bore diameter of the cylinder head. Lifter bore diameter: 34.000 − 34.021 mm (1.3386 − 1.3394 in.) (b) EM2196 Using a micrometer, measure the lifter diameter. Lifter diameter: 33.966 − 33.976 mm (1.3372 − 1.3376 in.) (c) Subtract the lifter diameter measurement from the lifter bore diameter measurement. Standard oil clearance: 0.024 − 0.055 mm (0.0009 − 0.0022 in.) Maximum oil clearance: 0.07 mm (0.0028 in.) If the oil clearance is greater than maximum, replace the lifter. If necessary, replace the cylinder head. 11. INSPECT AIR INTAKE CHAMBER Using a precision straight edge and thickness gauge, measure the surface contacting the intake manifold for warpage. Maximum warpage: 0.30 mm (0.0118 in.) If warpage is greater than maximum, replace the air intake chamber. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark EM−48 ENGINE MECHANICAL − CYLINDER HEAD 12. INSPECT INTAKE MANIFOLD Using a precision straight edge and thickness gauge, measure the surface contacting the cylinder head and air intake chamber for warpage. Maximum warpage: 0.30 mm (0.0118 in.) If warpage is greater than maximum, replace the manifold. 13. INSPECT EXHAUST MANIFOLDS Using a precision straight edge and thickness gauge, measure the surface contacting the cylinder head for warpage. Maximum warpage: 0.30 mm (0.0118 in.) If warpage is greater than maximum, replace the manifold. 14. INSPECT CHAIN TENSIONER Check that the plunger moves smoothly. P22604 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark EM−49 ENGINE MECHANICAL − CYLINDER HEAD REPLACEMENT 1. (a) (b) (c) Both intake and exhaust Bushing bore diameter mm (in.) Bushing size 11.492 − 11.513 (0.4524 − 0.4533) Use STD 11.542 − 11.563 (0.4544 − 0.4552) Use O/S 0.05 EM1Q6−01 REPLACE VALVE GUIDE BUSHINGS Gradually heat the cylinder head to 80 − 100°C (176 − 212°F). Using SST and a hammer, tap out the guide bushing. SST 09201−10000 (09201−01070), 09950−70010 (09951−07100) Using a caliper gauge, measure the bushing bore diameter of the cylinder head. (d) Select a new guide bushing (STD or O/S 0.05). If the bushing bore diameter of the cylinder head is greater than 11.513 mm (0.4533 in.), machine the bushing bore to the following dimension: 11.542 − 11.563 mm (0.4544 − 0.4552 in.) If the bushing bore diameter of the cylinder head is greater than 11.563 mm (0.4552 in.), replace the cylinder head. (e) Gradually heat the cylinder head to 80 − 100°C (176 − 212°F). (f) Using SST and a hammer, tap in a new guide bushing until it protrudes 8.2 − 8.6 mm (0.323 − 0.339 in.) from the cylinder head. SST 09201−10000 (09201−01070), 09950−70010 (09951−07100) (g) Using a sharp 7 mm reamer, ream the guide bushing to obtain the standard specified clearance (See page EM−40) between the guide bushing and valve stem. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark EM−50 ENGINE MECHANICAL − CYLINDER HEAD 2. (a) REPLACE SPARK PLUG TUBE GASKETS Using a screwdriver, pry out the tube gasket. (b) Using SST and a hammer, tap in a new tube gasket as shown in the illustration. SST 09950−60010 (09951−00480), 09950−70010 (09951−07150) Apply a light coat of MP grease to the gasket lip. (c) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark EM−51 ENGINE MECHANICAL − CYLINDER HEAD REASSEMBLY EM1E6−01 HINT: S S S Thoroughly clean all parts to be assembled. 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 SPARK PLUG TUBES HINT: When using a new cylinder head, spark plug tubes must be installed. (a) Mark the standard position away from the edge, onto the spark plug tube. Standard protrusion: 45.5 mm (1.791 in.) (b) Apply adhesive to the spark plug tube hole of the cylinder head. Sealant: Part No. 08833−00070, Adhesive 1324, THREE BOND 1324 or equivalent (c) Using a press, press in a new spark plug tube until there is 45.5 mm (1.791 in.) protruding from the camshaft bearing cap installation surface of the cylinder head. NOTICE: Avoid pressing a new spark plug tube in too far by measuring the amount of protrusion while pressing. 2. (a) INSTALL TVV Apply adhesive to 2 or 3 threads of the TVV. Adhesive: Part No.08833−00080, THREE BOND 1344, LOCTITE 242 or equivalent 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark EM−52 ENGINE MECHANICAL − CYLINDER HEAD (b) 3. 4. 5. Install the TVV. INSTALL ECT SENDER GAUGE INSTALL ECT CUT SWITCH INSTALL ECT SENSOR 6. (a) INSTALL VALVES Using SST, push in a new oil seal. SST 09236−00101 (09236−15010) HINT: Different oil seals are used for the intake and exhaust. (b) Install the valve (1), spring seat (2), valve spring (3) and spring retainer (4). (c) Using SST, compress the valve spring and place the 2 keepers around the valve stem. SST 09202−70020 (09202−00010) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark EM−53 ENGINE MECHANICAL (d) 7. (a) (b) 8. 9. 10. 11. 12. (a) (b) − CYLINDER HEAD Using a plastic−faced hammer, lightly tap the valve stem tip to ensure a proper fit. INSTALL VALVE LIFTERS AND SHIMS Install the valve lifter and shim. Check that the valve lifter rotates smoothly by hand. INSTALL ACCELERATOR CABLE BRACKET AND THROTTLE CABLE BRACKET INSTALL 2 ENGINE WIRE CLAMP BRACKETS INSTALL NO. 1 AND NO. 2 ENGINE HANGERS Torque: 41 N·m (420 kgf·cm, 30 ft·lbf) INSTALL NO. 1 WATER BYPASS HOSE ASSEMBLE AIR INTAKE CHAMBER AND INTAKE MANIFOLD ASSEMBLY Install 2 new gaskets and the air intake chamber with the 6 bolts and 2 nuts. Torque: 21 N·m (210 kgf·cm, 15 ft·lbf) Connect the vacuum sensing hose to the fuel pressure regulator. 13. INSTALL AIR INTAKE CHAMBER AND INTAKE MANIFOLD ASSEMBLY (a) Place a new gasket so that the rear mark is toward the rear side. (b) Install the intake manifold with the 10 bolts and 2 nuts. Torque: 21 N·m (210 kgf·cm, 15 ft·lbf) (c) Connect the 2 vacuum hoses to the TVV. 14. INSTALL HEATER INLET PIPE AND HOSE Install the heater hose to the cylinder head, and connect the pipe to the intake manifold with the 2 bolts. Torque: 21 N·m (210 kgf·cm, 15 ft·lbf) 15. INSTALL EGR PIPE (a) Temporarily install the union nut to the EGR valve. (b) Install a new gasket and the EGR pipe to the cylinder head with the 2 bolts. Torque: 21 N·m (210 kgf·cm, 15 ft·lbf) (c) Tighten the union nut. Torque: 78 N·m (800 kgf·cm, 58 ft·lbf) 16. INSTALL WATER OUTLET Install a new gasket and the water outlet with the 2 nuts. Torque: 21 N·m (210 kgf·cm, 15 ft·lbf) 17. INSTALL GENERATOR BRACKET Install the generator bracket with the 2 bolts. Torque: 43 N·m (440 kgf·cm, 32 ft·lbf) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark EM−54 ENGINE MECHANICAL − CYLINDER HEAD INSTALLATION EM1E7−01 1. INSTALL CYLINDER HEAD AND INTAKE MANIFOLD ASSEMBLY (a) Place the cylinder head on the cylinder head. (1) Apply seal packing to the 2 locations as shown. Seal packing: Part No. 08826−00080 or equivalent NOTICE: Do not apply too much seal packing (2) Place a new cylinder head gasket in position on the cylinder block. NOTICE: Be careful of the installation direction. (3) Place the cylinder head in position on the cylinder head gasket. (b) Install the cylinder head bolts. HINT: S The cylinder head bolts are tightened in 3 progressive steps (steps (b), (d) and (e)). S If any cylinder head bolt is broken or deformed, replace it. (1) Apply a light coat of engine oil on the threads and under the heads of the cylinder head bolts. (2) Install and uniformly tighten the 14 cylinder head bolts and plate washers in several passes, in the sequence shown. Torque: 39 N·m (400 kgf·cm, 29 ft·lbf) If any of the cylinder head bolts does not meet the torque specification, replace the cylinder head bolt. (3) (4) (5) (6) Mark the front of the cylinder head bolt head with paint. Retighten the cylinder head bolts by 90° in the numerical order shown. Retighten the cylinder head bolts by an additional 90°. Check that the painted mark is now facing rearward. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark EM−55 ENGINE MECHANICAL − CYLINDER HEAD (7) Install and torque the 2 mounting bolts. Torque: 21N·m (210 kgf·cm, 15 ft·lbf) 2. (a) ASSEMBLE EXHAUST CAMSHAFT Mount the hexagon wrench head portion of the camshaft in a vise. NOTICE: Be careful not to damage the camshaft. (b) Install the camshaft gear spring (1), camshaft sub−gear (2) and wave washer (3). HINT: Align the pins on the gears with the spring ends. (c) Using snap ring pliers, install the snap ring. (d) Insert a service bolt (A) into the service hole of the camshaft sub−gear. (e) Using a screwdriver, align the holes of the camshaft main gear and sub−gear by turning camshaft sub− gear clockwise, and install a service bolt (B). NOTICE: Be careful not to damage the camshaft. 3. INSTALL CAMSHAFTS NOTICE: Since the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being installed. If the camshaft is not kept level, the portion of the cylinder head receiving the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, the following steps should be carried out. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark EM−56 ENGINE MECHANICAL (a) − CYLINDER HEAD Install the intake camshaft. (1) Apply engine oil to the thrust portion of the intake camshaft. (2) Lightly place the intake camshaft on top of the cylinder head as shown in the illustration so that the No. 1 and No. 4 cylinder cam lobes face downward. (3) Lightly push the camshaft towards the front without applying excessive force. (4) (5) (6) (7) Place the No. 2 and No. 5 bearing caps in their proper location. Temporarily tighten these bearing cap bolts uniformly and alternately in several passes until the bearing caps are snug with the cylinder head. Place the No. 3, No. 4, No. 6 and No. 7 bearing caps in their proper location. Temporarily tighten these bearing cap bolts, alternately tightening the left and right bolts uniformly. (8) Place the No. 1 bearing cap in its proper location. When doing this, check that there is no gap between the cylinder head and the contact surface of bearing cap. (9) Temporarily tighten the bearing cap bolts, alternately tightening the left and right bolts uniformly. (10) Uniformly tighten the 14 bearing cap bolts in several passes. Torque: 16 N·m (160 kgf·cm, 12 ft·lbf) (b) 2 Dot Marks P22567 Install the exhaust camshaft. (1) Set the timing mark (2 dot marks) of the camshaft drive gear at approx. 35° angle by turning the hexagon wrench head portion of the intake camshaft with a wrench. A16077 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark EM−57 ENGINE MECHANICAL − (2) (3) (4) (5) (6) (7) (8) (9) CYLINDER HEAD Apply engine oil to thrust portion of the exhaust camshaft. Engage the exhaust camshaft gear to the intake camshaft gear by matching the timing marks (two dot marks) on each gear. Roll down the exhaust camshaft onto the bearing journals while engaging gears with each other. Lightly push the intake camshaft towards the front without applying excessive force. Install the No. 4 and No. 6 bearing caps in their proper location. Temporarily tighten the bearing cap bolts uniformly and alternately in several passes until the bearing caps are snug with the cylinder head. Place the No. 2, No. 3, No. 5 and No. 7 bearing caps in their proper location. Temporarily tighten these bearing cap bolts, alternately tightening the left and right bolts uniformly. (10) Place the No. 1 bearing cap in its proper location. When doing this, check that there is no gap between the cylinder head and the contact surface of bearing cap. (11) Temporarily tighten the bearing cap bolts, alternately tightening the left and right bolts uniformly. (12) Uniformly tighten the 14 bearing cap bolts in several passes. Torque: 16 N·m (160 kgf·cm, 12 ft·lbf) (13) Bring the service bolt installed in the driven sub− gear upward by turning the hexagon wrench head portion of the camshaft with a wrench. (14) Remove the service bolt. (15) Check that the intake and exhaust camshafts turn smoothly. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark EM−58 ENGINE MECHANICAL 1 Dot Mark P08374 − CYLINDER HEAD 4. (a) SET NO.1 CYLINDER TO TDC/COMPRESSION Turn the crankshaft pulley, and align its groove with the timing mark ”0” of the timing chain cover. (b) Turn the camshafts so that the timing marks with 1 and 2 dots will be in straight line on the cylinder head surface as shown in the illustration. A16075 5. INSTALL CAMSHAFT TIMING GEAR HINT: Check that the matchmarks on the camshaft timing gear and timing chain are aligned. (a) Place the gear over the straight pin of the intake camshaft. (b) Align the straight pin of distributor gear with the straight pin groove of the intake camshaft gear as shown. (c) Hold the intake camshaft with a wrench, install and torque the bolt. Torque: 74 N·m (750 kgf·cm, 54 ft·lbf) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark EM−59 ENGINE MECHANICAL − CYLINDER HEAD 6. (a) INSTALL CHAIN TENSIONER Place a new gasket so that the front mark is toward the front side. (b) Push the tensioner by hand until it touches the head installation surface, then install the 2 nuts. Tighten the 2 nuts. Torque: 21 N·m (210 kgf·cm, 15 ft·lbf) Front Mark (c) Push P09890 7. (a) CHECK VALVE TIMING Turn the crankshaft pulley, and align its groove with the timing mark ”0” of the timing chain cover. NOTICE: Always turn the crankshaft clockwise. (b) 1 Dot Mark P08374 A16075 Check that the timing marks (1 and 2 dots) of the camshaft drive and driven gears are in straight line on the cylinder head surface as shown in the illustration. If not, turn the crankshaft 1 revolution (360°) and align the marks as above. 8. CHECK AND ADJUST VALVE CLEARANCE (See page EM−4) Turn the camshaft and position the cam lobe upward and check and adjust the valve clearance. Valve clearance (Cold): 9. Intake 0.15 − 0.25 mm (0.006 − 0.010 in.) Exhaust 0.25 − 0.35 mm (0.010 − 0.041 in.) INSTALL SPARK PLUGS 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark EM−60 ENGINE MECHANICAL 10. (a) (b) (c) − CYLINDER HEAD INSTALL SEMI−CIRCULAR PLUG Remove any old packing (FIPG) material. Apply seal packing to the cylinder head installation surface of the semi−circular plug. Seal packing: Part No. 08826−00080 or equivalent Install the semi−circular plug to the cylinder head. P03789 11. (a) (b) Check that the timing marks with 1 and 2 dots are in straight line on the cylinder head surface as shown in the illustration. If not, turn the crankshaft 1 revolution (360°) and align the mark as above. 12. INSTALL CYLINDER HEAD COVER (a) Install the gasket to the cylinder head cover. (b) Install the cylinder head cover with the 13 bolts. 1 Dot Mark P08374 SET NO. 1 CYLINDER TO TDC/COMPRESSION Turn the crankshaft pulley, and align its groove with the timing mark ”0” of the timing chain cover. A16075 13. (a) INSTALL WATER BYPASS OUTLET AND PIPE Install a new O−ring to the water bypass outlet. (b) (c) (d) (e) Install 2 new O−rings to the water bypass pipe. Apply soapy water to the O−rings. Assemble the water bypass outlet and pipe. Install the water bypass outlet and pipe with the 2 bolts. Torque: 21 N·m (210 kgf·cm, 15 ft·lbf) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark EM−61 ENGINE MECHANICAL − CYLINDER HEAD 14. INSTALL HEATER PIPE Install a new gasket, the heater pipe and ground cable with the 2 bolts and 2 nuts. Torque: 20 N·m (200 kgf·cm, 14 ft·lbf) for bolt: 21 N·m (210 kgf·cm, 15 ft·lbf) for nut 15. INSTALL NO. 1 AND NO. 2 EXHAUST MANIFOLDS (a) Install 2 new gaskets, No. 1 exhaust manifold and No. 2 exhaust manifold with the 13 nuts. Torque: 39 N·m (400 kgf·cm, 29 ft·lbf) (b) Install the No. 1 heat insulator and No. 2 heat insulator with the 6 bolts. Torque: 19 N·m (195 kgf·cm, 14 ft·lbf) 16. INSTALL FRONT EXHAUST PIPE (a) Install 2 new gaskets and the front exhaust pipe with the 4 nuts. Torque: 63 N·m (630 kgf·cm, 46 ft·lbf) (b) Install the No. 1 support bracket with the 2 bolts. Torque: 24 N·m (240 kgf·cm, 17 ft·lbf) (c) Connect the clamp and tighten the clamp bolt. Torque: 19.5 N·m (195 kgf·cm, 14 ft·lbf) (d) Connect the front exhaust pipe to the rear TWC with a new gasket, 2 bolts and 2 nuts. Torque: 46 N·m (470 kgf·cm, 34 ft·lbf) 17. CONNECT NO. 2 WATER BYPASS PIPE Connect the bypass pipe to the cylinder head with the 3 bolts. Torque: 20 N·m (200 kgf·cm, 14 ft·lbf) 18. (a) (b) (c) (d) (e) (f) (g) CONNECT ENGINE WIRE Place the engine wire on the intake manifold. Connect the connectors. (1) Connect the 3 injector connectors. (2) Connect the EGR gas temp. sensor connector. Connect the clamp of the No.6 injector wire to the bracket. Connect the engine wire clamp. Connect the engine wire clamp. Connect the connectors. (1) Connect the connector for the emission control valve set assembly. (2) Connect the 3 injector connectors. Install the bolt holding the engine wire to the intake manifold. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark EM−62 ENGINE MECHANICAL (h) (i) (j) (k) − CYLINDER HEAD Connect the engine wire to the intake manifold and cylinder block with the 2 bolts. Connect the PNP switch connector. Connect the 2 heated oxygen sensor connectors. Connect the connectors. (1) Connect the Knock sensor connector. (2) Connect the oil level sensor connector. (3) Connect the 2 connectors to tthe ransmission. (4) Connect the starter connector. (l) (m) Connect the engine wire to the cylinder block with the bolt. Connect the connectors. (1) Connect the ECT sender gauge connector. (2) Connect the ECT cut switch connector. (3) Connect the ECT sensor connector. (4) Connect the knock sensor connector. (5) Connect the crankshaft position sensor connector. 19. CONNECT FUEL INLET HOSE Connect the fuel inlet hose to the fuel filter with 2 new gaskets and the union bolt. Torque: 29 N·m (300 kgf·cm, 22 ft·lbf) 20. INSTALL INTAKE MANIFOLD STAY Install the intake manifold stay with the 2 bolts. Torque: 36 N·m (360 kgf·cm, 26 ft·lbf) 21. (a) (b) (c) (d) 22. 23. INSTALL OIL DIPSTICKS AND GUIDES FOR ENGINE AND TRANSMISSION Install a new O−ring to the dipstick guide. Apply a light coat of engine oil on the O−ring. Push in the dipstick guide into the guide hole of the oil pan. Install the dipstick guide with the 2 bolts. Torque: 20 N·m (200 kgf·cm, 14 ft·lbf) INSTALL THROTTLE BODY (See page SF−48) INSTALL GENERATOR AND DRIVE BELTS (See page CH−19) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark EM−63 ENGINE MECHANICAL − CYLINDER HEAD 24. CONNECT NO. 3 WATER BYPASS HOSE 25. CONNECT RADIATOR INLET HOSE 26. CONNECT PS RESERVOIR TANK Connect the reservoir tank with the 3 bolts. Torque: 20 N·m (200 kgf·cm, 14 ft·lbf) 27. INSTALL DISTRIBUTOR (See page IG−11) 28. INSTALL NO. 2 AND NO. 3 CYLINDER HEAD COVERS Install the head covers with the 4 bolts. 29. CONNECT HEATER VALVE AND ENGINE WIRE TO COWL PANEL (a) Connect the heater valve with the 2 bolts. (b) Connect the engine wire and ground strap with the 2 bolts. 30. CONNECT HEATER HOSES 31. 32. 33. CONNECT FUEL RETURN HOSE CONNECT EVAP HOSE CONNECT BRAKE BOOSTER VACUUM HOSE 34. CONNECT CONNECTOR ON INTAKE MANIFOLD TO LH FENDER APRON CONNECT ENGINE GROUND STRAPS Connect the ground strap to the No. 1 engine hanger. Connect the ground strap to the air intake chamber. CONNECT THROTTLE CABLE TO THROTTLE BODY CONNECT ACCELERATOR CABLE TO THROTTLE BODY CONNECT CRUISE CONTROL ACTUATOR CABLE TO THROTTLE BODY 35. (a) (b) 36. 37. 38. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark EM−64 ENGINE MECHANICAL − CYLINDER HEAD 39. INSTALL AIR CLEANER HOSE AND CAP 40. INSTALL BATTERY TRAY AND BATTERY (a) Install the battery tray with the 5 bolts. (b) Connect the ground strap with the bolt. (c) Install the battery and hold−down clamp with the nuts. (d) Connect the battery cables. 41. FILL RADIATOR WITH ENGINE COOLANT 42. START ENGINE AND CHECK FOR LEAKS 43. ADJUST IGNITION TIMING (See page EM−10) 44. PERFORM ROAD TEST Check for abnormal noise, shock, slippage, correct shift points and smooth operation. 45. RECHECK ENGINE COOLANT LEVEL 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark EM−65 ENGINE MECHANICAL − ENGINE UNIT ENGINE UNIT EM1EC−01 COMPONENTS 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 568 Brought to you by BirfMark EM−66 ENGINE MECHANICAL − ENGINE UNIT 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 569 Brought to you by BirfMark EM−67 ENGINE MECHANICAL − ENGINE UNIT 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 570 Brought to you by BirfMark EM−68 ENGINE MECHANICAL − ENGINE UNIT 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 571 Brought to you by BirfMark EM−69 ENGINE MECHANICAL − ENGINE UNIT REMOVAL 1. 2. 3. DRAIN ENGINE COOLANT DRAIN ENGINE OIL REMOVE HOOD 4. (a) (b) (c) (d) REMOVE BATTERY AND BATTERY TRAY Disconnect the battery cables. Remove the nuts, hold−down clamp and battery. Remove the bolt and disconnect the ground strap. Remove the 5 bolts and battery tray. EM1ED−02 5. REMOVE RADIATOR GRILLE Remove the 5 screws, clip and radiator grille. 6. REMOVE RADIATOR (See page CO−14) 7. DISCONNECT OIL COOLER HOSE FROM OIL COOLER PIPE 8. REMOVE AIR CLEANER HOSE AND CAP 9. REMOVE AIR CLEANER CASE 10. DISCONNECT CRUISE CONTROL ACTUATOR CABLE FROM THROTTLE BODY 11. DISCONNECT ACCELERATOR CABLE FROM THROTTLE BODY 12. DISCONNECT HEATER HOSES 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark EM−70 ENGINE MECHANICAL 13. (a) (b) 14. 15. 16. (a) (b) 17. (a) (b) (c) (d) (e) (f) (g) (h) (i) (j) 18. (a) (b) − ENGINE UNIT DISCONNECT ENGINE WIRE AND HEATER VALVE FROM COWL PANEL Remove the 2 bolts and disconnect the engine wire and ground strap. Remove the 2 bolts and disconnect the heater valve. DISCONNECT BRAKE BOOSTER VACUUM HOSE DISCONNECT EVAP HOSE DISCONNECT FUEL HOSES Disconnect the fuel return hose. Remove the union bolt and 2 gaskets, and disconnect the fuel inlet hose from the fuel filter. DISCONNECT WIRES AND CONNECTORS Disconnect the 2 heated oxygen sensor connectors. Disconnect the DLC1 clamp. Disconnect the 2 oil pressure gauge connectors. Disconnect the generator wire and connector. Disconnect the connector on the intake manifold from the fender apron. Disconnect the high−tension cord from the ignition coil. Disconnect the ground strap from the No. 1 engine hanger. Disconnect the ground strap from the air intake chamber. Disconnect the starter wire. Disconnect the ground cable from the cylinder block. DISCONNECT A/C COMPRESSOR AND BRACKET Loosen the idler pulley nut and adjusting bolt, and remove the drive belt. Remove the 4 mounting bolts, and disconnect the compressor from the bracket. HINT: Put aside the compressor, and suspend it. (c) Remove the 5 bolts and A/C compressor bracket. 19. (a) (b) REMOVE RADIATOR PIPE Remove the 2 nuts holding the radiator pipe to the No. 1 oil pan. Disconnect the No. 2 radiator hose from the water inlet and remove the radiator pipe. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark EM−71 ENGINE MECHANICAL − ENGINE UNIT 20. DISCONNECT PS PRESSURE HOSE Remove the union bolt and 2 gaskets, and disconnect the pressure hose from the PS pump. 21. DISCONNECT PS RETURN HOSE Disconnect the return hose from the PS reservoir tank. 22. (a) (b) DISCONNECT ENGINE WIRE FROM CABIN Remove the 2 screws and glove compartment door. Remove the screw and speaker panel. (c) (d) Remove the screw, and disconnect the A/C amplifier. Disconnect the connectors. (1) Disconnect the 3 connectors from the ECM. (2) Disconnect the 2 connectors from the cowl wire. Pull out the engine wire from the cabin. (e) 23. (a) REMOVE STABILIZER BAR Remove the 2 bolts and disconnect stabilizer bar from the bracket. (b) Remove the bolt and nut, and remove the stabilizer bar from the axle housing. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark EM−72 ENGINE MECHANICAL − ENGINE UNIT 24. (a) (b) (c) (d) REMOVE FRONT AND REAR PROPELLER SHAFTS Put matchmarks on the flanges. Remove the 4 bolts and nuts. Remove the 4 nuts. Remove the propeller shaft. 25. (a) REMOVE TRANSFER SHIFT LEVER Remove the nut and transmission control rod. (b) (c) (d) (e) Remove the transfer shift lever knob. Remove 4 screws. Lift up the console slightly in order to disconnect the connector. Remove the console. (f) Remove the 3 bolts and console box. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark EM−73 ENGINE MECHANICAL − ENGINE UNIT (g) (h) Disconnect the 3 connectors. Remove the 10 bolts and the transfer shift lever boot and transmission shift lever assembly. (i) Pull out the pin and disconnect the shift rod. (j) Remove the 4 bolts, hose clamp and the transfer shift lever. 26. (a) (b) REMOVE FRONT EXHAUST PIPE Disconnect the heated oxygen sensor connector. Remove the 2 nuts and 2 bolts holding the front exhaust pipe to the rear TWC. Disconnect the front exhaust pipe, and remove the gasket. (c) (d) Loosen the clamp bolt and disconnect the clamp from the No.1 support bracket. (e) Remove the 2 bolts and No. 1 support bracket. (f) Remove the 4 nuts, front exhaust pipe and 2 gaskets. 27. DISCONNECT GROUND STRAP FROM HEAT INSULATOR 28. PLACE JACK UNDER TRANSMISSION Be sure to put a wooden block between the jack and the transmission oil pan to prevent damage. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark EM−74 ENGINE MECHANICAL 29. (a) − ENGINE UNIT (b) REMOVE FRAME CROSSMEMBER Remove the 2 nuts holding the crossmember to the engine rear mounting insulator. Remove the 8 bolts and crossmember. 30. (a) REMOVE ENGINE WITH TRANSMISSION Attach the engine hoist chain to the 2 engine hangers. (b) Remove the 2 nuts holding the engine front mounting insulators to the frame. (c) Lift the engine with transmission out of the vehicle slowly and carefully. NOTICE: Make sure that the engine is clear of all wiring and hoses. (d) Place the engine and transmission assembly onto the stand. 31. (a) (b) (c) (d) 32. (a) (b) REMOVE OIL DIPSTICK GUIDE FOR TRANSMISSION Disconnect the 2 breather hoses. Remove the 2 mounting bolts. Pull out the dipstick guide and dipstick from the transmission. Remove the O−ring from the dipstick guide. DISCONNECT ENGINE WIRE FROM TRANSMISSION Disconnect the PNP switch connector. Disconnect the 2 connectors from the transmission. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark EM−75 ENGINE MECHANICAL 33. (a) (b) 34. (a) (b) − ENGINE UNIT REMOVE STARTER Disconnect the starter connector. Remove the 2 bolts and starter. REMOVE A/T OIL COOLER PIPES FOR TRANSMISSION Remove the 3 clamp mounting bolts. Loosen the 2 union nuts, and remove the oil cooler pipes. P22609 35. DISCONNECT THROTTLE CABLE FROM THROTTLE BODY 36. REMOVE HOLE PLUG 37. REMOVE 6 TORQUE CONVERTER CLUTCH MOUNTING BOLT Turn the crankshaft to gain access to each bolt. Remove the 6 bolts. 38. REMOVE TRANSMISSION FROM ENGINE Remove the 10 bolts and transmission. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark EM−76 ENGINE MECHANICAL − ENGINE UNIT INSTALLATION EM1EE−02 1. CHECK TORQUE CONVERTER CLUTCH INSTALLATION Using calipers and straight edge, measure from the installed surface of the torque converter clutch to the front surface of the transmission. Correct distance: 15.7 mm (0.618 in.) or more If the distance is less than the specifications, check for an improper installation. 2. INSTALL TRANSMISSION TO ENGINE Install the transmission with the 7 bolts. Torque: 72 N·m (730 kgf·cm, 53 ft·lbf) 3. INSTALL TORQUE CONVERTER CLUTCH MOUNTING BOLTS Install the 6 bolts by turning the crankshaft. Torque: 55 N·m (550 kgf·cm, 41 ft·lbf) HINT: First install the green colored bolt and then the remaining 5 bolts. 4. INSTALL HOLE PLUG 5. CONNECT THROTTLE CABLE TO THROTTLE BODY 6. INSTALL A/T OIL COOLER PIPES FOR TRANSMISSION (a) Temporarily install the 3 mounting bolts. (b) Connect the 2 oil cooler pipes to the unions on the transmission. Tighten the union nuts. Torque: 34 N·m (350 kgf·cm, 25 ft·lbf) (c) Tighten the 3 clamp mounting bolts. 7. INSTALL STARTER (a) Install the starter with the 2 bolts. Torque: 39 N·m (400 kgf·cm, 29 ft·lbf) (b) Connect the starter connector. 8. CONNECT ENGINE WIRE TO TRANSMISSION (a) Connect the 2 connectors from the transmission. (b) Connect the PNP switch connector. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark EM−77 ENGINE MECHANICAL 9. (a) (b) (c) (d) (e) 10. (a) (b) (c) (d) (e) (f) 11. (a) (b) (c) 12. 13. 14. (a) (b) (c) (d) − ENGINE UNIT INSTALL OIL DIPSTICK GUIDE FOR TRANSMISSION Install a new O−ring to the dipstick guide. Apply a light coat of ATF to the O−ring. Connect the dipstick guide end to the tube of the oil pan, and install the dipstick guide with the 2 bolts. Install the dipstick. Connect the 2 breather hoses. INSTALL ENGINE AND TRANSMISSION ASSEMBLY IN VEHICLE Attach the engine hoist chain to the engine hangers. Lower the engine and transmission assembly into the engine compartment. Insert the stud bolts of the front engine mounting insulators into the stud bolt holes of the frame. Temporarily install the 2 nuts holding the engine front mounting insulators to the frame crossmember. Keep the engine level with a jack. Remove the hoist chain. INSTALL FRAME CROSSMEMBER Temporarily install the crossmember to the engine rear mounting insulator with the 2 nuts. Install the 8 bolts holding the crossmember to the frame. Torque: 61 N·m (620 kgf·cm, 45 ft·lbf) Tighten the 2 nuts holding the crossmember to the engine rear mounting insulator. Torque: 74 N·m (750 kgf·cm, 54 ft·lbf) TIGHTEN NUTS HOLDING ENGINE FRONT MOUNTING INSULATORS TO FRAME Torque: 74 N·m (750 kgf·cm, 54 ft·lbf) CONNECT GROUND STRAP TO HEAT INSULATOR INSTALL FRONT EXHAUST PIPE Install 2 new gaskets and the front exhaust pipe with the 4 nuts. Torque: 63 N·m (630 kgf·cm, 46 ft·lbf) Install the No.1 support bracket with the 2 bolts. Torque: 24 N·m (240 kgf·cm, 17 ft·lbf) Connect the clamp and tighten the clamp bolt. Torque: 19.5 N·m (195 kgf·cm, 14 ft·lbf) Connect the front exhaust pipe to the rear TWC with a new gasket, 2 bolts and 2 nuts. Torque: 46 N·m (470 kgf·cm, 34 ft·lbf) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark EM−78 ENGINE MECHANICAL − ENGINE UNIT 15. (a) INSTALL TRANSFER SHIFT LEVER Install the shift lever and hose clamp with the 4 bolts. Torque: 18 N·m (185 kgf·cm, 13 ft·lbf) (b) (c) (e) Connect the shift rod and install the pin. Install the transfer shift lever boot and transmission shift lever assembly with the 10 bolts. Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf) Connect the 3 connectors to the transmission shift lever assembly. Install the console box with the 3 bolts. (f) (g) (h) Connect the pattern select switch connector. Install the console with the 4 screws. Install the transfer shift lever knob. (i) (j) Shift the shift lever to N position. Fully turn the control shaft lever back and return 2 notches. It is now in neutral position. Connect the transmission control rod with the nut. Torque: 13 N·m (130 kgf·cm, 9 ft·lbf) (d) (k) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark EM−79 ENGINE MECHANICAL 16. (a) (b) 17. (a) (b) − ENGINE UNIT Differential Side: INSTALL FRONT AND REAR PROPELLER SHAFTS Align the matchmarks on the flanges and connect the flanges with the 4 bolts and nuts. Torque the bolts and nuts. Torque: 74 N·m (750 kgf·cm, 54 ft·lbf) for front shaft 88 N·m (900 kgf·cm, 65 ft·lbf)for rear shaft Transfer Side: INSTALL FRONT AND REAR PROPELLER SHAFTS Align the matchmarks on the flanges and connect the flanges with the 4 nuts. Torque the nuts. Torque: 74 N·m (750 kgf·cm, 54 ft·lbf) for front shaft 88 N·m (900 kgf·cm, 65 ft·lbf) for rear shaft 18. (a) INSTALL STABILIZER BAR Temporarily install the stabilizer bar to the axle housing with the bolt and nut. (b) Connect the stabilizer bar with the 2 bolts. Torque: 18 N·m (185 kgf·cm, 13 ft·lbf) Bounce the vehicle up and down to stabilize the suspension. (c) (d) Torque the bolt and nut holding the stabilizer bar to the axle housing. Torque: 25 N·m (260 kgf·cm, 19 ft·lbf) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark EM−80 ENGINE MECHANICAL − ENGINE UNIT 19. (a) (b) CONNECT ENGINE WIRE TO CABIN Push in the engine wire through the cowl panel. Connect the connectors. (1) Connect the 3 connectors to the ECM. (2) Connect the 2 connectors to the cowl wire. (c) Connect the A/C amplifier with the screw. (d) Install the speaker panel with the screw. (e) Install the glove compartment door with the 2 screws. 20. CONNECT PS RETURN HOSE Connect the return hose to the PS reservoir tank. 21. CONNECT PS PRESSURE HOSE Connect the PS pressure hose with 2 new gaskets and the union bolt. Torque: 56 N·m (575 kgf·cm, 42 ft·lbf) 22. INSTALL RADIATOR PIPE (a) Connect the No. 2 radiator hose to the water inlet. (b) Install the 2 nuts holding the radiator pipe to the No. 1 oil pan. Torque: 21 N·m (210 kgf·cm, 15 ft·lbf) 23. INSTALL A/C COMPRESSOR AND BRACKET (a) Install the A/C compressor bracket with the 5 bolts. Torque: 37 N·m (375 kgf·cm, 27 ft·lbf) (b) Install the A/C compressor with the 4 bolts. Torque: 25 N·m (250 kgf·cm, 18 ft·lbf) (c) Install and adjust the drive belt (See page CH−2). 24. CONNECT WIRES AND CONNECTORS (a) Connect the 2 heated oxygen sensor connectors. (b) Connect the DLC1 clamp. (c) Connect the 2 oil pressure gauge connectors. (d) Connect the generator wire and connector. (e) Connect the connector on the intake manifold to the fender apron. (f) Connect the high−tension cord to the ignition coil. (g) Connect the ground strap to the No. 1 engine hanger. (h) Connect the ground strap to the air intake chamber. (i) Connect the starter wire. (j) Connect the ground cable to the cylinder block. 25. (a) (b) CONNECT FUEL HOSES Connect the fuel inlet hose to the fuel filter with 2 new gaskets and the union bolt. Torque: 29 N·m (300 kgf·cm, 22 ft·lbf) Connect the fuel return hose. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark EM−81 ENGINE MECHANICAL − ENGINE UNIT 26. 27. 28. CONNECT EVAP HOSE CONNECT BRAKE BOOSTER VACUUM HOSE CONNECT HEATER VALVE AND ENGINE WIRE TO COWL PANEL (a) Connect the heater valve with the 2 bolts. (b) Connect the engine wire and ground strap with the 2 bolts. 29. CONNECT HEATER HOSES 30. CONNECT ACCELERATOR CABLE TO THROTTLE BODY 31. CONNECT CRUISE CONTROL ACTUATOR CABLE TO THROTTLE BODY 32. INSTALL AIR CLEANER CASE 33. INSTALL AIR CLEANER HOSE AND CAP 34. CONNECT OIL COOLER HOSE TO OIL COOLER PIPE 35. INSTALL RADIATOR (See page CO−16) 36. INSTALL RADIATOR GRILLE Install the radiator grille with the 5 screws and clip. 37. INSTALL BATTERY TRAY AND BATTERY (a) Install the battery tray with the 5 bolts. (b) Connect the ground strap with the bolt. (c) Install the battery and hold−down clamp with the nuts. (d) Connect the battery cables. 38. FILL WITH ENGINE OIL 39. FILL RADIATOR WITH ENGINE COOLANT 40. START ENGINE AND CHECK FOR LEAKS 41. CHECK AUTOMATIC TRANSMISSION FLUID LEVEL 42. CHECK IGNITION TIMING (See page EM−10) 43. INSTALL HOOD 44. PERFORM ROAD TEST Check for abnormal noise, shock, slippage, correct shift points and smooth operation. 45. RECHECK ENGINE COOLANT AND ENGINE OIL LEVELS 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark EM−82 ENGINE MECHANICAL − CYLINDER BLOCK CYLINDER BLOCK EM1EF−01 COMPONENTS 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 585 Brought to you by BirfMark EM−83 ENGINE MECHANICAL − CYLINDER BLOCK DISASSEMBLY EM1Q8−01 1. REMOVE DRIVE PLATE Uniformly loosen and remove the drive plate bolts, in several passes, in the sequence shown. 2. INSTALL ENGINE TO ENGINE STAND FOR DISASSEMBLY 3. REMOVE CYLINDER HEAD (See page EM−28) 4. REMOVE TIMING CHAIN AND GEARS (See page EM−13) 5. REMOVE OIL FILTER (See page LU−2) 6. REMOVE OIL FILTER UNION 7. REMOVE KNOCK SENSORS Using SST, remove the 2 knock sensors. SST 09816−30010 8. (a) (b) REMOVE PS PUMP Remove the 2 nuts and pump. Remove the O−ring from the pump. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark EM−84 ENGINE MECHANICAL − CYLINDER BLOCK 9. (a) (b) REMOVE RH ENGINE MOUNTING BRACKET Remove the nut and insulator. Remove the 4 bolts and bracket. 10. (a) (b) REMOVE LH ENGINE MOUNTING BRACKET Remove the nut and insulator. Remove the 4 bolts and bracket. 11. REMOVE OIL COOLER COVER AND OIL COOLER Remove the 10 bolts, 2 nuts, oil cooler cover with the oil cooler and gasket. 12. REMOVE REAR OIL SEAL RETAINER Remove the 4 bolts and retainer. 13. CHECK CONNECTING ROD THRUST CLEARANCE Using a dial indicator, measure the thrust clearance while moving the connecting rod back and forth. Standard thrust clearance: 0.160 − 0.262 mm (0.0063 − 0.0103 in.) Maximum thrust clearance: 0.362 mm (0.0143 in.) If the thrust clearance is greater than maximum, replace the connecting rod assembly. If necessary, replace the crankshaft. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark EM−85 ENGINE MECHANICAL 14. (a) (b) (c) − CYLINDER BLOCK REMOVE CONNECTING ROD CAPS AND CHECK OIL CLEARANCE Check the matchmarks on the connecting rod cap and connecting rod to ensure correct reassembly. Remove the connecting rod cap nuts. Using a plastic−faced hammer, lightly tap the connecting rod bolts and lift off the connecting rod cap. HINT: Keep the lower bearing inserted with the connecting rod cap. (d) Cover the connecting rod bolts with a short piece of hose to protect the crankshaft from damage. (e) Clean the crank pin and bearing. (f) Check the crank pin and bearing for pitting and scratches. If the crank pin or bearing is damaged, replace the bearings. If necessary, grind or replace the crankshaft. (g) Lay a strip of Plastigage across the crank pin. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark EM−86 ENGINE MECHANICAL − CYLINDER BLOCK (h) Install the connecting rod cap with the 2 nuts (See page EM−103). NOTICE: Do not turn the crankshaft. (i) Remove the 2 nuts and connecting rod cap (See procedure (b) and (c) above). (j) Measure the Plastigage at its widest point. Standard oil clearance: STD 0.032 − 0.050 mm (0.0013 − 0.0020 in.) U/S 0.25 0.033 − 0.073 mm (0.0013 − 0.0029 in.) Maximum oil clearance: 0.10 mm (0.0039 in.) If the oil clearance is greater than maximum, replace the bearings. If necessary, grind or replace the crankshaft. HINT: If using a standard bearing, replace with one having the same number. If the number of the bearing cannot be determined, select the correct bearing by adding together the numbers imprinted on the connecting rod and crankshaft, then selecting the bearing with the same number as the total. There are 5 sizes of standard bearings, marked ”2”, ”3”, ”4”, ”5” and ”6” accordingly. Number marked Connecting rod 1 2 3 Crankshaft 1 2 3 1 2 3 1 2 3 Use bearing 2 3 4 3 4 5 4 5 6 EXAMPLE: Connecting rod ”3” + Crankshaft ”1” = Total number 4 (Use bearing ”4”) Reference Connecting rod big end inside diameter: Mark ”1” 60.526 − 60.532 mm (2.3829 − 2.3831 in.) Mark ”2” 60.532 − 60.538 mm (2.3831 − 2.3834 in.) Mark ”3” 60.538 − 60.544 mm (2.3834 − 2.3836 in.) Crankshaft crank pin diameter: Mark ”1” 56.994 − 57.000 mm (2.2439 − 2.2441 in.) Mark ”2” 56.988 − 56.994 mm (2.2436 − 2.2439 in.) Mark ”3” 56.982 − 56.988 mm (2.2434 − 2.2436 in.) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark EM−87 ENGINE MECHANICAL − CYLINDER BLOCK Standard sized bearing center wall thickness: Mark ”2” 1.744 − 1.747 mm (0.0687 − 0.0688 in.) Mark ”3” 1.747 − 1.750 mm (0.0688 − 0.0689 in.) Mark ”4” 1.750 − 1.753 mm (0.0689 − 0.0690 in.) Mark ”5” 1.753 − 1.756 mm (0.0690 − 0.0691 in.) Mark ”6” 1.756 − 1.759 mm (0.0691 − 0.0693 in.) (k) Completely remove the Plastigage. 15. REMOVE PISTON AND CONNECTING ROD ASSEMBLIES Using a ridge reamer, remove the all carbon from the top of the cylinder. Push the piston, connecting rod assembly and upper bearing through the top of the cylinder block. (a) (b) HINT: Keep the bearings, connecting rod and cap together. Arrange the piston and connecting rod assemblies in correct order. 16. CHECK CRANKSHAFT THRUST CLEARANCE Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver. Standard thrust clearance: 0.020 − 0.220 mm (0.0008 − 0.0087 in.) Maximum thrust clearance: 0.30 mm (0.0118 in.) If the thrust clearance is greater than maximum, replace the thrust washers as a set. Thrust washer thickness: S S P04620 17. (a) STD 2.440 − 2.490 mm (0.0961 − 0.0980 in.) O/S 0.125 2.503 − 2.553 mm (0.0985 − 0.1005 in.) O/S 0.250 2.565 − 2.615 mm (0.1010 − 0.1030 in.) REMOVE MAIN BEARING CAPS AND CHECK OIL CLEARANCE Uniformly loosen and remove the main bearing cap bolts in several passes, in the sequence shown. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark EM−88 ENGINE MECHANICAL (b) − CYLINDER BLOCK Using the removed main bearing cap bolts, pry the main bearing cap back and forth, and remove the main bearing caps, lower bearings and (No.4 main bearing cap only) lower thrust washers. HINT: S S Keep the lower bearing and main bearing cap together. Arrange the main bearing caps and lower thrust washers in correct order. Lift out the crankshaft. (c) HINT: Keep the upper bearing and upper thrust washers together with the cylinder block. (d) (e) Clean each main journal and bearing. Check each main journal and bearing for pitting and scratches. If the journal or bearing is damaged, replace the bearings. If necessary, grind or replace the crankshaft. (f) (g) Place the crankshaft on the cylinder block. Lay a strip of Plastigage across each journal. (h) Install the main bearing caps (See page EM−103). NOTICE: Do not turn the crankshaft. (i) Remove the main bearing caps (See procedure (a) and (b) above). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark EM−89 ENGINE MECHANICAL (j) − CYLINDER BLOCK Measure the Plastigage at its widest point. Standard clearance: STD 0.042 − 0.060 mm (0.0017 − 0.0024 in.) U/S 0.25 0.041 − 0.081 mm (0.0016 − 0.0032 in.) Maximum clearance: 0.10 mm (0.0039 in.) If the oil clearance is greater than maximum, replace the bearings. If necessary, grind or replace the crankshaft. HINT: If using a standard bearing, replace with one having the same number. If the number of the bearing cannot be determined, select the correct bearing by adding together the numbers imprinted on the cylinder block and crankshaft, then selecting the bearing with the same number as the total. There are 5 sizes of standard bearings, marked ”2”, ”3”, ”4”, ”5” and ”6” accorkingly. Number marked Cylinder block 1 2 3 Crankshaft 1 2 3 1 2 3 1 2 3 Use bearing 2 3 4 3 4 5 4 5 6 EXAMPLE: Cylinder block ”2” + Crankshaft ”1” = Total number 3 (Use bearing ”3”) Reference Cylinder block main journal bore diameter: Mark ”1” 74.026 − 74.032 mm (2.9144 − 2.9146 in.) Mark ”2” 74.032 − 74.038 mm (2.9146 − 2.9149 in.) Mark ”3” 74.038 − 74.044 mm (2.9149 − 2.9151 in.) Crankshaft main journal diameter: Mark ”1” 68.994 − 69.000 mm (2.7163 − 2.7165 in.) Mark ”2” 68.988 − 68.994 mm (2.7161 − 2.7163 in.) Mark ”3” 68.982 − 68.988 mm (2.7158 − 2.7161 in.) Standard bearing center wall thickness: (k) 18. (a) (b) Mark ”2” 2.489 − 2.492 mm (0.0980 − 0.0981 in.) Mark ”2” 2.492 − 2.495 mm (0.0981 − 0.0982 in.) Mark ”3” 2.495 − 2.498 mm (0.0982 − 0.0983 in.) Mark ”4” 2.498 − 2.501 mm (0.0983 − 0.0985 in.) Mark ”5” 2.501 − 2.504 mm (0.0985 − 0.0986 in.) Completely remove the Plastigage. REMOVE CRANKSHAFT Lift out the crankshaft. Remove the upper main bearings and upper thrust washers from the cylinder block. HINT: Arrange the main bearings and thrust washers in correct order. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark EM−90 ENGINE MECHANICAL − CYLINDER BLOCK 19. REMOVE CHECK VALVES AND OIL NOZZLES Remove the 6 check valves and oil nozzles. 20. REMOVE CYLINDER BLOCK ORIFICE 21. CHECK FIT BETWEEN PISTON AND PISTON PIN Try to move the piston back and forth on the piston pin. If any movement is felt, replace the piston and pin as a set. P04628 22. (a) REMOVE PISTON RINGS Using a piston ring expander, remove the 2 compression rings. (b) Remove the 2 side rails and oil ring by hand. HINT: Arrange the rings in correct order only. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark EM−91 ENGINE MECHANICAL − CYLINDER BLOCK 23. (a) (b) DISCONNECT CONNECTING ROD FROM PISTON Using a small screwdriver, pry out the 2 snap rings. Gradually heat the piston to 80 − 90°C (176 − 194°F). (c) Using plastic−faced hammer and brass bar, lightly tap out the piston pin and remove the connecting rod. HINT: S S The piston and pin are a matched set. Arrange the pistons, pins, rings, connecting rods and bearings in correct order. P03870 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark EM−92 ENGINE MECHANICAL − CYLINDER BLOCK INSPECTION 1. (a) (b) EM1EH−02 CLEAN CYLINDER BLOCK Using a gasket scraper, remove all the gasket material from the top surface of the cylinder block. Using a soft brush and solvent, thoroughly clean the cylinder block. 2. (a) INSPECT CYLINDER BLOCK Inspect for flatness. Using a precision straight edge and feeler gauge, measure the surfaces contacting the cylinder head gasket for warpage. Maximum warpage: 0.05 mm (0.0020 in.) If warpage is greater than maximum, replace the cylinder block. (b) Visually check the cylinder for vertical scratches. If deep scratches are present, rebore all the 6 cylinders. If necessary, replace the cylinder block. (c) Inspect the cylinder bore diameter. HINT: There are 3 sizes of the standard cylinder bore diameter, marked ”1”, ”2” and ”3” accordingly. The mark is stamped on the top of the cylinder block. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark EM−93 ENGINE MECHANICAL − CYLINDER BLOCK Using a cylinder gauge, measure the cylinder bore diameter at positions A, B and C in the thrust and axial directions. Standard diameter: STD Mark ”1” 100.000 − 100.010 mm (3.9370 − 3.9374 in.) Mark ”2” 100.010 − 100.020 mm (3.9374 − 3.9378 in.) Mark ”3” 100.020 − 100.030 mm (3.9378 − 3.9382 in.) Maximum diameter: STD 100.23 mm (3.9461 in.) O/S 0.50 100.73 mm (3.9658 in.) O/S 1.00 101.23 mm (3.9854 in.) If the diameter is greater than maximum, rebore all the 6 cylinders. If necessary, replace the cylinder block. (d) Remove the cylinder ridge. If the wear is less than 0.2 mm (0.008 in.), using a ridge reamer, grind the top of the cylinder. (e) Inspect the main bearing cap bolts. Using vernier calipers, measure the thread outside diameter of the bolt. Standard outside diameter: 10.85 − 11.00 mm (0.4271 − 0.4331 in.) Minimum outside diameter: 10.6 mm (0.417 in.) If the diameter is less than minimum, replace the bolt. (f) Inspect the cylinder blockl oil orifice for clogging. If necessary, replace the orifice. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark EM−94 ENGINE MECHANICAL − CYLINDER BLOCK 3. INSPECT BEARING OF OIL PUMP DRIVE SHAFT GEAR Check the bearing for pitting and scratches. If the bearing is damaged, replace the cylinder block. 4. (a) CLEAN PISTON Using a gasket scraper, remove the carbon from the piston top. (b) Using a groove cleaning tool or broken ring, clean the piston ring grooves. (c) Using solvent and a brush, thoroughly clean the piston. NOTICE: Do not use a wire brush. 5. INSPECT PISTON AND CONNECTING ROD (a) Inspect the piston oil clearance. HINT: There are 3 sizes of the standard piston diameter, marked ”1”, ”2” and ”3”. The mark is stamped on the piston top. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark EM−95 − ENGINE MECHANICAL CYLINDER BLOCK (1) Using a micrometer, measure the piston diameter at right angles to the piston pin center line, 42 mm (1.65 in.) from the piston head. Piston diameter: STD Mark ”1” Mark ”2” Mark ”3” 99.950 − 99.960 mm (3.9350 − 3.9354 in.) 99.960 − 99.970 mm (3.9354 − 3.9358 in.) 99.970 − 99.980 mm (3.9358 − 3.9362 in.) O/S 0.50 100.450 − 100.480 mm (3.9547 − 3.9559 in.) O/S 1.00 100.950 − 100.980 mm (3.9744 − 3.9756 in.) (2) Measure the cylinder bore diameter in the thrust directions (See step 2). (3) Subtract the piston diameter measurement from the cylinder bore diameter measurement. Standard oil clearance: 0.040 − 0.060 mm (0.0016 − 0.0024 in.) Maximum oil clearance: 0.080 mm (0.0031 in.) If the oil clearance is greater than maximum, replace all the 6 pistons and rebore all the 6 cylinders. If necessary, replace the cylinder block. HINT: Use new cylinder block: Use a piston with the same number mark as the cylinder bore diameter marked on the cylinder block. (b) Inspect the piston ting groove clearance. Using a feeler gauge, measure the clearance between new piston ring and the wall of the piston ring groove. Ring groove clearance: No. 1 0.040 − 0.080 (0.0016 − 0.0031 in.) No. 2 0.030 − 0.070 (0.0012 − 0.0028 in.) If the clearance is greater than maximum, replace the piston. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark EM−96 ENGINE MECHANICAL (c) − CYLINDER BLOCK Inspect the piston ring end gap. (1) Insert the piston ring into the cylinder bore. (2) Using a piston, push the piston ring a little beyond the bottom of the ring travel, 125 mm (4.92 in.) from the top of the cylinder block. 125 mm P04002 (3) Using a feeler gauge, measure the end gap. Standard end gap: No. 1 0.300 − 0.520 mm (0.0118 − 0.0205 in.) No. 2 0.450 − 0.670 mm (0.0177 − 0.0264 in.) Oil (Side rail) 0.150 − 0.520 mm (0.0059 − 0.0205 in.) Maximum end gap: EM7639 No. 1 1.12 mm (0.0441 in.) No. 2 1.17 mm (0.0461 in.) Oil (Side rail) 1.12 mm (0.0441 in.) If the end gap is greater than maximum, replace the piston ring. If the end gap is greater than maximum, even with a new piston ring, rebore all the 6 cylinders or replace the cylinder block. (d) Inspect the piston pin fit. At 80 − 90°C (176 − 194°F), you should be able to push the piston pin into the piston pin hole with your thumb. (e) Using a rod aligner and feeler gauge, check the connecting rod alignment. (1) Check for out−of−alignment. Maximum out−of−alignment: 0.05 mm (0.0020 in.) per 100 mm (3.94 in.) If out−of−alignment is greater than maximum, replace the connecting rod assembly. P03829 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark EM−97 ENGINE MECHANICAL − CYLINDER BLOCK (2) 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. P03828 (f) Inspect the piston pin oil clearance. (1) Using a caliper gauge, measure the inside diameter of the connecting rod bushing. Bushing inside diameter: 26.008 − 26.020 mm (1.0239 − 1.0244 in.) P03868 (2) EM0227 Using a micrometer, measure the piston pin diameter. Piston pin diameter: 26.000 − 26.012 mm (1.0236 − 1.0241 in.) (3) Subtract the piston pin diameter measurement from the bushing inside diameter measurement. Standard oil clearance: 0.004 − 0.012 mm (0.0002 − 0.0005 in.) Maximum oil clearance: 0.05 mm (0.0020 in.) If the oil clearance is greater than maximum, replace the bushing. If necessary, replace the piston and piston pin as a set (See page EM−99). (g) Inspect the connecting rod bolts. Install the cap nut to the connecting rod bolt. Check that the cap nut can be turned easily by hand to the end of the thread. If the cap nut cannot be turned easily, measure the outside diameter of the connecting rod bolt with vernier calipers. Standard outside diameter: 8.40 − 8.60 mm (0.3307 − 0.3386 in.) Minimum outside diameter: 8.00 mm (0.3150 in.) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark EM−98 ENGINE MECHANICAL − CYLINDER BLOCK HINT: If the location of this area cannot be judged by visual inspection, measure the outer diameter at the location shown in the illustration. If the outside diameter is less than minimum, replace the connecting rod bolt and nut as a set. 6. (a) INSPECT CRANKSHAFT Inspect for circle runout. (1) Place the crankshaft on V−blocks. (2) Using a dial indicator, measure the circle runout at the center journal. Maximum circle runout: 0.06 mm (0.0024 in.) If the circle runout is greater than maximum, replace the crankshaft. (b) Inspect the main journals and crank pins. (1) Using a micrometer, measure the diameter of each main journal and crank pin. Main journal diameter: STD 68.982 − 69.000 mm (2.7158 − 2.7165 in.) U/S 0.25 68.745 − 68.755 mm (2.7065 − 2.7069 in.) Crank pin diameter: STD 56.982 − 57.000 mm (2.2434 − 2.2441 in.) U/S 0.25 56.745 − 56.755 mm (2.2341 − 2.2344 in.) If the diameter is not as specified, check the oil clearance (See page EM−83). If necessary, grind or replace the crankshaft. (2) Check each main journal and crank pin for taper and out−of−round as shown. Maximum taper and out−of−round: 0.02 mm (0.0008 in.) If the taper and out−of−round is greater than maximum, replace the crankshaft. 7. IF NECESSARY, GRIND AND HONE MAIN JOURNALS AND/OR CRANK PINS Grind and hone the main journals and/or crank pins to the finished undersized diameter. Install new main journal and/or crankshaft pin undersized bearings. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark EM−99 ENGINE MECHANICAL − CYLINDER BLOCK REPLACEMENT EM1EI−02 1. (a) REPLACE CONNECTING ROD BUSHING Using SST and a press, press out the bushing. SST 09950−60010 (09951−00280), 09950−70010 (09951−07100) (b) Align the oil holes of a new bushing and the connecting rod. (c) Using SST and a press, press in the bushing. SST 09950−60010 (09951−00280), 09950−70010 (09951−07100) (d) Using a pin hole grinder, hone the bushing to obtain the standard specified cliarance (See page EM−92) between the bushing and piston pin. (e) Check the piston pin fit at normal room temperature. Coat the piston pin with engine oil, and push it into the connecting rod with your thumb. P03827 P03867 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark EM−100 ENGINE MECHANICAL 2. − CYLINDER BLOCK REPLACE OVERSIZED (O/S) PISTONS FOR CYLINDER BORING HINT: S S (a) Bore all the 6 cylinders for the O/S piston outside diameter. Replace all the piston rings with ones to match the O/S pistons. Keep 6 new O/S pistons. O/S piston diameter: O/S 0.50 100.450 − 100.480 mm (3.9547 − 3.9559 in.) O/S 1.00 100.950 − 100.980 mm (3.9744 − 3.9756 in.) (b) Using a micrometer, measure the piston diameter at right angles to the piston pin center line, 42 mm (1.65 in.) from the piston head. (c) Calculate the amount of each cylinder is to be rebored as follows: Size to be rebored = P + C − H P = Piston diameter C = Piston oil clearance 0.040 − 0.060 mm (0.0016 − 0.0024 in.) H = Allowance for honing 0.02 mm (0.0008 in.) or less (d) Bore and hone the cylinders to calculated dimensions. Maximum honing: 0.02 mm (0.0008 in.) NOTICE: Excess honing will destroy the finished roundness. 3. REPLACE CRANKSHAFT FRONT OIL SEAL HINT: There are 2 methods ((a) and (b)) to replace the oil seal. (a) If the timing chain cover is removed from the cylinder block: (1) Using a screwdriver and a hammer, tap out the oil seal. P04907 (2) Using SST and a hammer, tap in a new oil seal until its surface is flush with the timing chain cover edge. SST 09316−60011 (09316−00011, 09316−00051) (3) Apply MP grease to the oil seal lip. NOTICE: Do not let foreign matter get onto the lip of the oil seal. SST P08469 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark EM−101 ENGINE MECHANICAL − CYLINDER BLOCK (b) If the timing chain cover is installed to the cylinder block: (1) Using a screwdriver, pry out the oil seal. NOTICE: Be careful not to damage the crankshaft. Tape the screwdriver tip. P05005 (2) Apply MP grease to a new oil seal lip. NOTICE: Do not let foreign matter get onto the lip of the oil seal. (3) Using SST and a hammer, tap in the oil seal until its surface is flush with the timing chain cover edge. SST 09316−60011 (09316−00011, 09316−00051) SST P08506 4. REPLACE CRANKSHAFT REAR OIL SEAL HINT: There are 2 methods ((a) and (b)) to replace the oil seal. (a) If the rear oil seal retainer is removed from the cylinder block: (1) Using a screwdriver and a hammer, tap out the oil seal. P04518 (2) Using SST and a hammer, tap in a new oil seal until its surface is flush with the rear oil seal edge. SST 09223−15030, 09950−70010 (09951−07150) NOTICE: Do not let foreign matter get onto the lip of the oil seal. SST P04970 (b) If the rear oil seal retainer is installed to the cylinder block: (1) Using a knife, cut off the oil seal lip. (2) Using a screwdriver, pry out the oil seal. NOTICE: Be careful not to damage the crankshaft. Tape the screwdriver tip. Cut Position P08643 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark EM−102 ENGINE MECHANICAL − CYLINDER BLOCK (3) Using SST and a hammer, tap in a new oil seal until its surface is flush with the rear oil seal retainer edge. SST 09223−15030, 09950−70010 (09951−07150) NOTICE: Do not let foreign matter get onto the lip of the oil seal. (4) Check that the lip of the oil seal is not bent inward. CORRECT WRONG P23172 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark EM−103 ENGINE MECHANICAL − CYLINDER BLOCK EM1EJ−01 REASSEMBLY HINT: S Thoroughly clean all parts to be assembled. Before installing the parts, apply new engine oil to all slidining and rotating surfaces. Replace all gaskets, O−rings and oil seals with new parts. 1. (a) (b) ASSEMBLE PISTON AND CONNECTING ROD Install a new snap ring on one side of the piston pin hole. Gradually heat the piston to 80 − 90°C (176 − 194°F). (c) (d) Coat the piston pin with engine oil. Align the front marks of the piston and connecting rod, and push in the piston pin with your thumb. Install a new snap ring on the other side of the piston pin hole. S S P04409 (e) 2. (a) INSTALL PISTON RINGS Install the oil ring expander and 2 side rails by hand. (b) Using a piston ring expander, install the 2 compression rings with the code mark facing upward. Code mark: No. 1 1R No. 2 2R 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark EM−104 ENGINE MECHANICAL − CYLINDER BLOCK (c) Position the piston rings so that the ring ends are as shown. NOTICE: Do not align the ring ends. 3. (a) (b) INSTALL BEARINGS Align the bearing claw with the groove of the connecting rod or connecting rod cap. Install the bearings in the connecting rod and connecting rod cap. 4. INSTALL CYLINDER BLOCK ORIFICE 5. (a) INSTALL OIL NOZZLES AND CHECK VALVES Align the pin of the oil nozzle with the pin hole of the cylinder block. Install the oil nozzle with the check valve. Install the 6 oil nozzles and check valves. Torque: 25 N·m (250 kgf·cm, 18 ft·lbf) (b) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark EM−105 ENGINE MECHANICAL − CYLINDER BLOCK 6. (a) INSTALL MAIN BEARINGS Align the bearing claw with the claw groove of the cylinder block, and push in the 7 upper bearings. (b) Align the bearing claw with the claw groove of the main bearing cap, and push in the 7 lower bearings. HINT: A number is marked on each main bearing cap to indicate the installation position. P03813 P05520 A16079 7. INSTALL UPPER THRUST WASHERS Install the 2 thrust washers under the No.4 journal position of the cylinder block with the oil grooves facing outward. 8. PLACE CRANKSHAFT ON CYLINDER BLOCK 9. (a) INSTALL MAIN BEARING CAPS AND LOWER THRUST WASHERS Place the main bearing caps and lower thrust washers on the cylinder block. (1) Install the 2 thrust washers on the No.4 bearing cap with the grooves facing outward. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark EM−106 ENGINE MECHANICAL (2) − CYLINDER BLOCK Install the 7 main bearing caps in their proper locations. HINT: Each bearing cap has a number and front mark. (b) Install the main bearing cap bolts. HINT: S The main bearing cap bolts are tightened in 2 progressive steps (steps (b) and (d)). S If any of the main bearing cap bolts is broken or deformed, replace it. (1) Apply a light coat of engine oil on the threads and under the heads of the main bearings cap bolts. (2) Install and uniformly tighten the 14 bolts of the main bearing caps, in several passes, in the sequence shown. Torque: 74 N·m (750 kgf·cm, 54 ft·lbf) If any one of the main bearing cap bolts does not meet the torque specification, replace the main bearing cap bolt. (3) (c) (d) 10. (a) Mark the front of the main bearing cap bolt with paint. (4) Retighten the main bearing cap bolts by 90° in the numerical order shown above. (5) Check that the painted mark is now at a 90° angle to the front. Check that the crankshaft turns smoothly. Check that the crankshaft thrust clearance (See page EM−83). INSTALL PISTON AND CONNECTING ROD ASSEMBLIES Cover the connecting rod bolts with a short piece of hose to protect the crankshaft from damage. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark EM−107 ENGINE MECHANICAL − CYLINDER BLOCK (b) Using a piston ring compressor, push the correctly numbered piston and connecting rod assemblies into each cylinder with the front mark of the piston facing forward. 11. (a) INSTALL CONNECTING ROD CAP Place the connecting rod cap on the connecting rod. (1) Match the numbered connecting rod cap with the connecting rod. (2) Install the connecting rod cap with the front mark facing for ward. (b) Install the connecting rod cap nuts. HINT: S The connecting rod cap nuts are tightened in 2 progressive steps (steps (b) and (d)). S If any connecting rod bolt is broken or deformed, replace it. (1) Apply a light coat of engine oil on the threads and under the nuts of the connecting rod cap. (2) Install and alternately tighten the nuts of the connecting rod cap in several passes. Torque: 48 N·m (490 kgf·cm, 35 ft·lbf) If any one of the connecting rod cap nuts does not meet the torque specification, replace the connecting rod bolt and cap nut as a set. (3) (4) Mark the front of the connecting rod cap nut and bolt with paint. Retighten the connecting rod cap nuts 90° as shown. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark EM−108 ENGINE MECHANICAL − CYLINDER BLOCK (5) (c) (d) 12. (a) P04615 (b) Check that the painted mark on the nut is at 90° angle in relation to the mark on the bolt. Check that the crankshaft turns smoothly. Check that the connecting rod thrust clearance (See page EM−83). INSTALL REAR OIL SEAL RETAINER Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the retainer and cylinder block. S Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and sealing groove. S Thoroughly clean all components to remove all the loose material. S Using a non−residue solvent, clean both sealing surfaces. Apply seal packing to the retainer as shown in the illustration. Seal packing: Part No. 08826−00080 or equivalent S Install a nozzle that has been cut to a 2 − 3 mm (0.08 − 0.12 in.) opening. HINT: Avoid applying an excessive amount to the surface. S Parts must be assembled within 5 minutes of application. Otherwise the material must be removed and reapplied. S Immediately remove nozzle from the tube and reinstall cap. (c) Install the retainer with the 4 bolts. Torque: 21 N·m (210 kgf·cm, 15 ft·lbf) 13. INSTALL OIL COOLER COVER AND OIL COOLER Install a new gasket, the oil cooler cover and oil cooler with the 10 bolts and 2 nuts. Torque: 21 N·m (210 kgf·cm, 15 ft·lbf) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark EM−109 ENGINE MECHANICAL 14. (a) (b) 15. (a) (b) 16. (a) (b) − CYLINDER BLOCK INSTALL LH ENGINE MOUNTING BRACKET Install the bracket with the 4 bolts. Torque: 69 N·m (700 kgf·cm, 51 ft·lbf) Install the insulator with the nut. Torque: 72 N·m (730 kgf·cm, 43 ft·lbf) INSTALL RH ENGINE MOUNTING BRACKET Install the bracket with the 4 bolts. Torque: 69 N·m (700 kgf·cm, 51 ft·lbf) Install the insulator with the nut. Torque: 72 N·m (730 kgf·cm, 43 ft·lbf) INSTALL PS PUMP Place a new O−ring to the pump. Install the pump with the 2 nuts. Torque: 36 N·m (370 kgf·cm, 27 ft·lbf) 17. INSTALL KNOCK SENSORS Using SST, install the 2 knock sensors. SST 09816−30010 Torque: 44 N·m (450 kgf·cm, 33 ft·lbf) 18. INSTALL OIL FILTER UNION Torque: 44 N·m (450 kgf·cm, 33 ft·lbf) 19. INSTALL OIL FILTER (See page LU−2) 20. INSTALL TIMING CHAIN (See page EM−19) 21. INSTALL CYLINDER HEAD (See page EM−54) 22. REMOVE ENGINE STAND 23. INSTALL DRIVE PLATE (a) Install the front spacer, drive plate and rear plate on the crankshaft. (b) Install and uniformly tighten the 10 drive plate bolts, in several passes, in the sequence shown. Torque: 100 N·m (1,000 kgf·cm, 74 ft·lbf) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark EM−110 ENGINE MECHANICAL − EXHAUST SYSTEM EXHAUST SYSTEM EM0EE−10 COMPONENTS 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 613 Brought to you by BirfMark IG−1 IGNITION − IGNITION SYSTEM IGNITION SYSTEM ON−VEHICLE INSPECTION 1. (a) (b) IG0IB−02 CHECK THAT SPARK OCCURS Disconnect the high−tension cords (from the ignition coil) from the distributor cap. Hold the end approx. 12.5 mm (0.50 in.) from the body ground. Check if spark occurs while engine is being cranked. (c) HINT: To prevent gasoline from being injected from injectors during this test, crank the engine for no more than 1 − 2 seconds at a time. If the spark does not occur, do the test as follows: SPARK TEST NO CHECK CONNECTION OF IGNITION COIL, IGNITER AND BAD Connect securely. DISTRIBUTOR CONNECTOR OK CHECK RESISTANCE OF HIGH−TENSION CORD BAD Replace the cord(s). (See step 8) Maximum resistance: 25 kΩ per cord OK CHECK POWER SUPPLY TO IGNITION COIL AND IGNITER BAD Check wiring between ignition switch to ignition coil and igniter. 1. Turn ignition switch to ON. 2. Check that there is battery voltage at ignition coil positive (+) terminal. OK CHECK RESISTANCE OF IGNITION COIL (See step 24) Resistance: Cold Hot Primary 0.36 − 0.55 Ω 0.45 − 0.65 Ω Secondary 9.0 − 15.4 kΩ 11.4 − 18.1 kΩ Replace the ignition coil. BAD OK CHECK RESISTANCE OF SIGNAL GENERATOR (PICKUP COIL) (See step 32) Resistance: Cold Hot G1 and G− 185 − 275 Ω 240 − 325 Ω G2 and G− 185 − 275 Ω 240 − 325 Ω NE and G− 185 − 275 Ω 240 − 325 Ω OK CHECK AIR GAP OF DISTRIBUTOR (See step 31) Air gap: 0.2 − 0.4 mm (0.008 −0.016 in.) OK CHECK IGT SIGNAL FROM ECM (See page DI−93) Replace the distributor housing assembly. BAD BAD Replace the distributor housing assembly. BAD Check wiring between ECM, ignition coil and igniter, and then try another ECM. OK TRY ANOTHER IGNITER 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 735 Brought to you by BirfMark IG−2 IGNITION 2. 3. 4. − IGNITION SYSTEM REMOVE NO.2 PCV HOSE REMOVE AIR CLEANER HOSE DISCONNECT THROTTLE CABLE 5. REMOVE NO.2 AND NO.3 CYLINDER HEAD COVERS Remove the 4 bolts and head covers. 6. (a) DISCONNECT HIGH−TENSION CORDS FROM SPARK PLUGS Remove the 2 mounting bolts of the No.1 and No.2 cord clamps. P22687 (b) Disconnect the high−tension cords at the rubber boot. Do not pull on the cords. NOTICE: Pulling on or bending the cords may damage the conductor inside. P08512 7. (a) DISCONNECT HIGH−TENSION CORDS FROM DISTRIBUTOR CAP AND IGNITION COIL Using a screwdriver, lift up the lock claw and disconnect the holder from the distributor cap (ignition coil). 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 736 Brought to you by BirfMark IG−3 IGNITION − IGNITION SYSTEM (b) Disconnect the high−tension cord at the grommet. Do not pull on the cord. NOTICE: Pulling on or bending the cords may damage the conductor inside.Do not wipe any of the oil from the grommet after the high−tension cord is disconnected. 8. INSPECT HIGH−TENSION CORD RESISTANCE Using an ohmmeter, measure the resistance. Maximum resistance: 25 kΩ per cord If the resistance is greater than maximum, check the terminals. If necessary, replace the high−tension cord. 9. (a) RECONNECT HIGH−TENSION CORDS TO DISTRIBUTOR CAP AND IGNITION COIL Assemble the holder and grommet. HINT: Connect the high−tension cords to the distributor cap as shown in the illustration. (b) Align the spline of the distributor (ignition coil) with the spline of the holder, and push in the cord. 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 737 Brought to you by BirfMark IG−4 IGNITION − IGNITION SYSTEM NOTICE: Check that the holder is correctly installed to the grommet and distributor cap as shown in the illustration. (c) Check that the lock claw of the holder is engaged by lightly pulling the holder. 10. RECONNECT HIGH−TENSION CORDS TO SPARK PLUGS Secure the high−tension cords with the cord clamps as shown in the illustration. (a) 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 738 Brought to you by BirfMark IG−5 IGNITION (b) − IGNITION SYSTEM Install the No.1 and No.2 cord clamps with the 2 bolts. 11. INSTALL NO.2 AND NO.3 CYLINDER HEAD COVERS Install the head covers with the 4 bolts. 12. CONNECT THROTTLE CABLE 13. INSTALL AIR CLEANER HOSE Install the air cleaner hose with the 2 clamp bolts. 14. INSTALL NO.2 PCV HOSE 15. DISCONNECT HIGH−TENSION CORDS FROM SPARK PLUGS 16. REMOVE SPARK PLUGS Using a 16 mm plug wrench, remove the spark plug. 17. CLEAN SPARK PLUGS Using a spark plug cleaner or wire brush, clean the spark plug. IG0152 18. VISUALLY INSPECT SPARK PLUGS Check the spark plug for electrode wear, threads damage and insulator damage. If abnormal, replace the plugs. Recommended spark plugs: ND: K16R−U NGK: BKR5EYA P03783 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 739 Brought to you by BirfMark IG−6 IGNITION − IGNITION SYSTEM 19. ADJUST ELECTRODE GAP Carefully bend the outer electrode to obtain the correct electrode gap. Correct electrode gap: 0.8 mm (0.031 in.) P03792 20. INSTALL SPARK PLUGS Using a 16 mm plug wrench, install the spark plug. Torque: 20 N·m (200 kgf·cm, 14 ft·lbf) 21. RECONNECT HIGH−TENSION CORDS TO SPARK PLUGS NOTICE: ”Cold” and ”Hot” in the following sentences express the temperature of the coils themselves. ”Cold” is from −10°C (14°F) to 50°C (122°F) and ”Hot” is from 50°C (122°F) to 100°C (212°F). 22. DISCONNECT IGNITION COIL CONNECTOR 23. DISCONNECT HIGH−TENSION CORD 24. INSPECT PRIMARY COIL RESISTANCE Using an ohmmeter, measure the resistance between the positive (+) and negative (−) terminals. Primary coil resistance: Cold: 0.36 − 0.55 Ω Hot: 0.45 − 0.65 Ω If the resistance is not as specified, replace the ignition coil. 25. INSPECT SECONDARY COIL RESISTANCE Using an ohmmeter, measure the resistance between the positive (+) and high−tension terminals. Secondary coil resistance: Cold: 9.0 − 15.4 kΩ Hot: 11.4 − 18.1 kΩ If the resistance is not as specified, replace the ignition coil. 26. RECONNECT HIGH−TENSION CORD 27. RECONNECT IGNITION COIL CONNECTOR 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 740 Brought to you by BirfMark IG−7 IGNITION − IGNITION SYSTEM NOTICE: ”Cold” and ”Hot” in the following sentences express the temperature of the coils themselves. ”Cold” is from −10°C (14°F) to 50°C (122°F) and ”Hot” is from 50°C (122°F) to 100°C (212°F). 28. DISCONNECT DISTRIBUTOR CONNECTOR 29. REMOVE DISTRIBUTOR CAP WITHOUT DISCONNECTING HIGH−TENSION CORDS 30. REMOVE ROTOR 31. INSPECT AIR GAPS Using a thickness gauge, measure the gap between the signal rotor and the pickup coil projection. Air gap: 0.2 − 0.4 mm (0.008 − 0.016 in.) If the gap is not as specified, replace the distributor housing. 32. INSPECT SIGNAL GENERATOR (PICKUP COIL) RESISTANCE Using an ohmmeter, check that the resistance of the pickup coil. Pickup coil resistance: Cold G1 and GĜ G2 and GĜ NE and GĜ 185 − 275 Ω 185 − 275 Ω 185 − 275 Ω Hot G1 and GĜ G2 and GĜ NE and GĜ 240 − 325 Ω 240 − 325 Ω 240 − 325 Ω If the resistance is not as specified, replace the distributor housing. 33. REINSTALL ROTOR 34. REINSTALL DISTRIBUTOR CAP 35. RECONNECT DISTRIBUTOR CONNECTOR NOTICE: ”Cold” and ”Hot” in the following sentences express the temperature of the sensor itself. ”Cold” is from −10°C (14°F) to 50°C (122°F) and ”Hot” is from 50°C (122°F) to 100°C (212°F). 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 741 Brought to you by BirfMark IG−8 IGNITION 36. − IGNITION SYSTEM DISCONNECT CRANKSHAFT POSITION SENSOR CONNECTOR AND BRACKET 37. P22961 INSPECT CRANKSHAFT POSITION SENSOR RESISTANCE Using an ohmmeter, measure the resistance between the terminals. Resistance (NEę − NEĜ): Cold: 1,630 − 2,740 Ω Hot: 2,065 − 3,225 Ω If the resistance is not as specified, replace the crankshaft position sensor. 38. RECONNECT CRANKSHAFT POSITION SENSOR BRACKET AND CONNECTOR 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 742 Brought to you by BirfMark IG−9 IGNITION − DISTRIBUTOR DISTRIBUTOR IG0IC−01 COMPONENTS 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 743 Brought to you by BirfMark IG−10 IGNITION − DISTRIBUTOR REMOVAL IG0ID−01 1. 2. DISCONNECT DISTRIBUTOR CONNECTOR REMOVE DISTRIBUTOR CAP WITHOUT DISCONNECTING HIGH−TENSION CORDS 3. (a) SET NO.1 CYLINDER TO TDC/COMPRESSION Turn the crankshaft pulley until the timing mark is aligned with ”0” mark on the timing chain cover. (b) Check that the distributor rotor direction is as shown. If not, turn the crankshaft pulley one complete revolution. 4. REMOVE DISTRIBUTOR (a) Remove the hold−down bolt and pull out the distributor. (b) Remove the O−ring from the distributor housing. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark IG−11 IGNITION − DISTRIBUTOR INSTALLATION IG0IE−01 1. CHECK NO.1 CYLINDER TO TDC/COMPRESSION If necessary, remove the cylinder head cover, and check these conditions: S Turn the crankshaft pulley and align its groove with the timing mark ”0” of the timing chain cover. Verify that the timing marks with 1 and 2 dots are in straight line on the cylinder head surface as shown in the illustration. If not, turn the crankshaft 1 revolution (360°) and align the mark as above. S 2. INSTALL DISTRIBUTOR (a) Install a new O−ring to the distributor. HINT: Always use a new O−ring when installing the distributor. (b) (c) (d) (e) 3. 4. 5. Align the groove of the distributor housing with the protrusion on the driven gear. Apply a light coat of engine oil on the O−ring. Insert the distributor, aligning the center of the flange with that of the bolt hole on the cylinder head. Lightly tighten the hold−down bolt. INSTALL DISTRIBUTOR CAP CONNECT DISTRIBUTOR CONNECTOR CHECK IGNITION TIMING (See page EM−10) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark IG−12 IGNITION − CRANKSHAFT POSITION SENSOR CRANKSHAFT POSITION SENSOR IG0JW−01 COMPONENTS 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 746 Brought to you by BirfMark IG−13 IGNITION − CRANKSHAFT POSITION SENSOR REMOVAL IG0JX−01 1. 2. REMOVE ENGINE UNDER COVER REMOVE CRANKSHAFT POSITION SENSOR PROTECTOR Remove the 3 bolts and crankshaft position sensor protector. Torque: 20 N·m (200 kgf·cm, 14 ft·lbf) 3. DISCONNECT CRANKSHAFT POSITION SENSOR BRACKET AND CONNECTOR 4. REMOVE CRANKSHAFT POSITION SENSOR Remove the bolt, 2 nuts and crankshaft position sensor. Torque: Bolt A: 20 N·m (200 kgf·cm, 14 ft·lbf) Nut B: 9 N·m (90 kgf·cm, 78 in.·lbf) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark IG−14 IGNITION − CRANKSHAFT POSITION SENSOR IG0JY−01 INSTALLATION Installation is in the reverse order of removal (See page IG−13). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark LU−1 LUBRICATION − OIL AND FILTER OIL AND FILTER LU08N−03 INSPECTION LU0817 1. CHECK ENGINE OIL QUALITY Check the oil for deterioration, entry of water, discoloring or thinning. If the quality is visibly poor, replace the oil. Oil grade: API grade SH Energy−Conserving II multigrade engine oil or ILSAC multigrade engine oil. Recommended viscosity is as shown in the illustration, with SAE 5W−30 being the preferred engine 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 ”F” mark. EM1759 3. Oil Pressure Gauge P22601 Adhesive P08343 REMOVE OIL PRESSURE SWITCH, AND INSTALL OIL PRESSURE GAUGE 4. WARM UP ENGINE Allow the engine to warm up to normal operating temperature. 5. CHECK OIL PRESSURE Oil pressure: At idle 29 kPa (0.3 kgf/cm2, 4.3 psi) or more At 3,000 rpm 245 − 490 kPa (2.5 − 5.0 kgf/cm2, 36 − 71 psi) 6. REMOVE OIL PRESSURE GAUGE AND REINSTALL OIL PRESSURE SWITCH (a) Remove the oil pressure gauge. (b) Apply adhesive to 2 or 3 threads of the oil pressure switch. Adhesive: Part No. 08833−00080, THREE BOND 1344, LOCTITE 242 or equivalent (c) Reinstall the oil pressure switch. 7. START ENGINE AND CHECK FOR LEAKS 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 712 Brought to you by BirfMark LU−2 LUBRICATION − OIL AND FILTER REPLACEMENT CAUTION: Prolonged and repeated contact with mineral oil will result in the removal of natural fats from the skin, leading to dryness, irritation and dermatitis. In addition, used engine oil contains potentially harmful contaminants which may cause skin cancer.Care should be taken, therefore, when changing engine oil to minimize the frequency and length of time your skin is exposed to used engine oil. Protective clothing and gloves that cannot be penetrated by oil should be worn. The skin should be thoroughly washed with soap and water, or use water−less hand cleaner, to remove any used engine oil. Do not used gasoline, thinners, or solvents.In order to preserve the environment, used oil and used oil filters must be disposed of only at designated disposal sites. 1. DRAIN ENGINE OIL (a) Remove the oil filler cap. (b) Remove the oil drain plug, and drain the oil into a container. 2. REPLACE OIL FILTER (a) Using SST, remove the oil filter. SST 09228−44011 (b) Check and clean the oil filter installation surface. (c) Apply clean engine oil to the gasket of a new oil filter. (d) Lightly screw the oil filter into place, and tighten it until the gasket contacts the seat. LU0KE−03 (e) 3. (a) (b) (c) 4. 5. Using SST, tighten it an additional 3/4 turn. SST 09228−44011 FILL WITH ENGINE OIL Clean and install the oil drain plug with a new gasket. Torque: 25 N·m (250 kgf·cm, 18 ft·lbf) Fill with new engine oil. Oil grade: See step 1 in oil pressure check Capacity: Drain and refill w/ Oil filter change 7.2 liters (7.5 US qts, 6.3 lmp. qts) w/o Oil filter change 6.9 liters (7.3 US qts, 6.1 lmp. qts) Dry fill 8.0 liters (8.5 US qts, 7.0 lmp. qts) Reinstall the oil filler cap. START ENGINE AND CHECK FOR LEAKS RECHECK ENGINE OIL LEVEL 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark LU−3 LUBRICATION − OIL PUMP OIL PUMP LU0KF−04 COMPONENTS 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 714 Brought to you by BirfMark LU−4 LUBRICATION − OIL PUMP 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 715 Brought to you by BirfMark LU−5 LUBRICATION − OIL PUMP REMOVAL LU0KG−02 HINT: When repairing the oil pump, the oil pan and strainer should be removed and cleaned. 1. DRAIN ENGINE OIL 2. REMOVE ENGINE UNDER COVER 3. DRAIN ENGINE COOLANT 4. REMOVE RADIATOR (See page CO−14) 5. (a) (b) DISCONNECT A/C COMPRESSOR AND BRACKET Loosen the idler pulley nut and adjusting bolt, and remove the drive belt. Remove the 4 mounting bolts, and disconnect the compressor from the bracket. HINT: Put aside the compressor, and suspend it. (c) Remove the 5 bolts and A/C compressor bracket. 6. (a) (b) REMOVE RADIATOR PIPE Disconnect the No.2 radiator hose from the water inlet. Remove the 2 nuts and radiator pipe. 7. REMOVE WATER PUMP Remove the 4 bolts, 2 nuts, water pump and gasket. 8. REMOVE CYLINDER HEAD (See page EM−28) 9. DISCONNECT OIL COOLER PIPE BRACKET FROM NO.1 OIL PAN 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark LU−6 LUBRICATION 10. (a) (b) − OIL PUMP REMOVE OIL LEVEL SENSOR Remove the 4 bolts and level sensor. Remove the gasket from the level sensor. 11. REMOVE BOLTS HOLDING NO.1 OIL PAN TO TRANSMISSION HOUSING Remove the 6 bolts. 12. (a) REMOVE NO.2 OIL PAN Remove the 17 mounting bolts and 2 nuts. (b) Insert the blade of SST between the No.1 and No.2 oil pans, cut off applied sealer and remove the No.2 oil pan. SST 09032−00100 NOTICE: Be careful not to damage the No.2 oil pan contact surface of the No.1 oil pan.Be careful not to damage the oil pan flange. 13. (a) REMOVE NO.1 OIL PAN Remove the 21 mounting bolts and 2 nuts. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark LU−7 LUBRICATION − OIL PUMP (b) Remove the No.1 oil pan by prying the portions (A) between the cylinder block and No.1 oil pan with a screwdriver. NOTICE: Be careful not to damage the contact surfaces of the cylinder block and No.1 oil pan. P22576 14. REMOVE OIL PAN BAFFLE PLATE Remove the bolt, 7 nuts and baffle plate. 15. REMOVE OIL STRAINER Remove the bolt, 2 nuts, oil strainer and gasket. 16. REMOVE CRANKSHAFT PULLEY (See page EM−13) 17. REMOVE DRIVE BELT IDLER PULLEY Remove the bolt and idler pulley. 18. REMOVE OIL PUMP (TIMING CHAIN COVER) (See page EM−13) 19. REMOVE TIMING CHAIN AND CAMSHAFT TIMING GEAR 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark LU−8 LUBRICATION − OIL PUMP DISASSEMBLY LU08R−03 1. REMOVE DRIVE AND DRIVEN ROTORS Remove the 7 screws, pump cover, drive rotor, driven rotor and gasket. HINT: At the time of installation, place a new gasket on the pump body. 2. REMOVE RELIEF VALVE Remove the plug, gasket, spring and relief valve. Torque: 49 N·m (500 kgf·cm, 36 ft·lbf) HINT: At the time of installation, install a new gasket to the plug. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark LU−9 LUBRICATION − OIL PUMP INSPECTION LU0KH−01 1. INSPECT RELIEF VALVE Coat the valve with engine oil and check that it falls smoothly into the valve hole by its own weight. If it does not, replace the relief valve. If necessary, replace the oil pump assembly. 2. INSPECT ROTOR BODY CLEARANCE Using a thickness gauge, measure the clearance between the driven rotor and body. Standard body clearance: 0.100 − 0.170 mm (0.0039 − 0.0067 in.) Maximum body clearance: 0.30 mm (0.0118 in.) If the body clearance is greater than maximum, replace the rotors as a set. If necessary, replace the oil pump assembly. 3. INSPECT ROTOR SIDE CLEARANCE Using a thickness gauge and precision straight edge, measure the clearance between the rotors and precision straight edge. Standard side clearance: 0.030 − 0.090 mm (0.0012 − 0.0035 in.) Maximum side clearance: 0.15 mm (0.0059 in.) If the side clearance is greater than maximum, replace the rotors as a set. If necessary, replace the oil pump assembly. 4. INSPECT ROTOR TIP CLEARANCE Using a thickness gauge, measure the clearance between the drive and driven rotor tips. Standard tip clearance: 0.030 − 0.160 mm (0.0012 − 0.0063 in.) Maximum tip clearance: 0.25 mm (0.0098 in.) If the tip clearance is greater than maximum, replace the rotors as a set. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark LU−10 LUBRICATION − OIL PUMP LU08T−03 REPLACEMENT REPLACE CRANKSHAFT FRONT OIL SEAL (See page EM−99) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark LU−11 LUBRICATION − OIL PUMP LU0KJ−01 REASSEMBLY Reassembly is in the reverse order of disassembly (See page LU−8). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark LU−12 LUBRICATION − OIL PUMP INSTALLATION LU0KI−02 1. SET CRANKSHAFT Turn the crankshaft until the set key on the crankshaft facing downward. 2. INSTALL TIMING CHAIN AND CAMSHAFT TIMING GEAR (See page EM−19) 3. INSTALL OIL PUMP (TIMING CHAIN COVER)(See page EM−19) 4. INSTALL DRIVE BELT IDLER PULLEY Install the pulley with the bolt. Torque: 43 N·m (440 kgf·cm, 32 ft·lbf) 5. INSTALL CRANKSHAFT PULLEY (See page EM−19) 6. INSTALL OIL STRAINER Install a new gasket and the oil strainer with the bolt and 2 nuts. Torque: 20 N·m (200 kgf·cm, 14 ft·lbf) 7. INSTALL OIL PAN BAFFLE PLATE Install the baffle plate with the bolt and 7 nuts. Torque: 9.0 N·m (90 kgf·cm, 78 in.·lbf) 8. INSTALL NO.1 OIL PAN (a) Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the oil pan, oil pump and cylinder block. S Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and sealing grooves. S Thoroughly clean all components to remove all the loose material. S Using a non−residue solvent, clean both sealing surfaces. (b) Apply seal packing to the No.1 oil pan as shown in the illustration. Seal packing: Part No. 08826−00080 or equivalent S Install a nozzle that has been cut to a 3 − 4 mm (0.12 − 0.16 in.) opening. HINT: Avoid applying an excessive amount to the surface. S Parts must be assembled within 5 minutes of application. Otherwise the material must be removed and reapplied. S Immediately remove nozzle from the tube and reinstall cap. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark LU−13 LUBRICATION − OIL PUMP (c) Install a new gasket in position. (d) Pour in approximately 15 cm3 (0.9 cu in.) of engine oil into oil pump hole. Install the No.1 oil pan with the 21 bolts and 2 nuts. Torque: 14 mm head: 44 N·m (440 kgf·cm, 32 ft·lbf) 12 mm head: 20 N·m (200 kgf·cm, 14 ft·lbf) INSTALL NO.2 OIL PAN Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surface of the No.1 oil pan. S Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and sealing grooves. S Thoroughly clean all components to remove all the loose material. S Using a non−residue solvent, clean both sealing surfaces. (e) 9. (a) (b) Apply seal packing to the No.2 oil pan as shown in the illustration. NOTICE: Do not use a solvent which will affect the painted surfaces. Seal packing: Part No. 08826−00080 or equivalent S Install a nozzle that has been cut to a 2 − 3 mm (0.08 − 0.12 in.) opening or 3 − 4 mm (0.012 − 0.016 in.) opening. HINT: Avoid applying an excessive amount to the surface. S Parts must be assembled within 5 minutes of application. Otherwise the material must be removed and reapplied. S Immediately remove nozzle from the tube and reinstall cap. (c) Install the No.2 oil pan with the 17 bolts and 2 nuts. Torque: 7.8 N·m (80 kgf·cm, 69 in.·lbf) Torque: 8.8 N·m (90 kgf·cm, 78 in.·lbf) 10. INSTALL BOLTS HOLDING NO.1 OIL PAN TO TRANSMISSION HOUSING 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark LU−14 LUBRICATION − OIL PUMP Install the 6 bolts. Torque: 72 N·m (730 kgf·cm, 53 ft·lbf) 11. (a) (b) INSTALL OIL LEVEL SENSOR Install a new gasket to the level sensor. Install the level sensor with the 4 bolts. Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf) 12. CONNECT OIL COOLER PIPE BRACKET TO NO.1 OIL PAN 13. INSTALL CYLINDER HEAD(See page EM−54) 14. INSTALL WATER PUMP Install a new gasket and water pump with the 4 bolts and 2 nuts. Torque: 21 N·m (210 kgf·cm, 15 ft·lbf) 15. INSTALL RADIATOR PIPE (a) Connect the No.2 radiator hose to the water inlet. (b) Install the 2 nuts holding the radiator pipe to the No.1 oil pan. Torque: 21 N·m (210 kgf·cm, 15 ft·lbf) 16. INSTALL A/C COMPRESSOR AND BRACKET (a) Install the A/C compressor bracket with the 5 bolts. Torque: 37 N·m (375 kgf·cm, 27 ft·lbf) (b) Install the A/C compressor with the 4 bolts. Torque: 25 N·m (250 kgf·cm, 18 ft·lbf) (c) Install and adjust the drive belt (See page CH−2). 17. INSTALL RADIATOR (See page CO−16) 18. INSTALL ENGINE UNDER COVER 19. FILL WITH ENGINE OIL 20. START ENGINE AND CHECK FOR LEAKS 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark LU−15 LUBRICATION − OIL COOLER OIL COOLER LU08W−03 COMPONENTS 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 726 Brought to you by BirfMark LU−16 LUBRICATION − OIL COOLER REMOVAL LU0KK−02 1. 2. DRAIN ENGINE COOLANT REMOVE AIR CLEANER CAP AND HOSE 3. (a) (b) REMOVE FRONT EXHAUST PIPE Disconnect the heated oxygen sensor connector. Remove the 2 nuts and 2 bolts holding the front exhaust pipe to the rear TWC. Disconnect the front exhaust pipe, and remove the gasket. (c) (d) (e) (f) Loosen the clamp bolt and disconnect the clamp from the No.1 support bracket. Remove the 2 bolts and No.1 support bracket. Remove the 4 nuts, front exhaust pipe and 2 gaskets. 4. (a) REMOVE NO.1 EXHAUST MANIFOLD Remove the 3 bolts and No.1 heat insulator. (b) Remove the 6 nuts, exhaust manifold and gasket. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark LU−17 LUBRICATION 5. − OIL COOLER REMOVE OIL PRESSURE SWITCH 6. REMOVE OIL COOLER AND OIL COOLER COVER ASSEMBLY Remove the 10 bolts, 2 nuts, oil cooler and oil cooler cover assembly and gasket. 7. SEPARATE OIL COOLER AND OIL COOLER COVER Remove the 4 nuts, oil cooler and 2 gaskets from the oil cooler cover. 8. REMOVE RELIEF VALVE Remove the plug, gasket, spring and relief valve. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark LU−18 LUBRICATION − OIL COOLER INSPECTION LU08Y−03 1. INSPECT RELIEF VALVE Coat the valve with engine oil and check that it falls smoothly into the valve hole by its own weight. If it doesn’t, replace the relief valve. If necessary, replace the oil cooler cover. 2. INSPECT OIL COOLER Check the oil cooler for damage or clogging. If necessary, replace the oil cooler. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark LU−19 LUBRICATION − OIL COOLER INSTALLATION LU08Z−04 1. INSTALL RELIEF VALVE Install the relief valve, spring and a new gasket with the plug. Torque: 37 N·m (375 kgf·cm, 27 ft·lbf) 2. ASSEMBLE OIL COOLER AND OIL COOLER COVER Install 2 new gaskets and the oil cooler to the oil cooler cover with the 4 nuts. Torque: 17 N·m (170 kgf·cm, 12 ft·lbf) 3. INSTALL OIL COOLER AND OIL COOLER COVER ASSEMBLY Install a new gasket, the oil cooler and oil cooler cover assembly with the 10 bolts and 2 nuts. Torque: 21 N·m (210 kgf·cm, 15 ft·lbf) 4. (a) Adhesive (b) 5. (a) P08343 (b) 6. (a) (b) (c) (d) 7. 8. 9. 10. INSTALL OIL PRESSURE SWITCH Apply adhesive to 2 or 3 threads of the oil pressure switch. Adhesive: Part No. 08833−00080, THREE BOND 1344, LOCTITE 242 or equivalent Install the oil pressure switch. INSTALL NO.1 EXHAUST MANIFOLD Install a new gasket and the exhaust manifold with the 6 nuts. Torque: 39 N·m (400 kgf·cm, 29 ft·lbf) Install the heat insulator with the 3 bolts. Torque: 19 N·m (195 kgf·cm, 14 ft·lbf) INSTALL FRONT EXHAUST PIPE Install 2 new gaskets and the front exhaust pipe with the 4 nuts. Torque: 63 N·m (630 kgf·cm, 46 ft·lbf) Install the No.1 support bracket with the 2 bolts. Torque: 24 N·m (240 kgf·cm, 17 ft·lbf) Connect the clamp and tighten the clamp bolt. Torque: 19.5 N·m (195 kgf·cm, 14 ft·lbf) Connect the front exhaust pipe to the rear TWC with a new gasket, 2 bolts and 2 nuts. Torque: 46 N·m (470 kgf·cm, 34 ft·lbf) INSTALL AIR CLEANER CAP AND HOSE FILL RADIATOR WITH ENGINE COOLANT START ENGINE AND CHECK FOR LEAKS CHECK ENGINE OIL 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark LU−20 LUBRICATION − OIL NOZZLE OIL NOZZLE LU0KL−01 COMPONENTS 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 731 Brought to you by BirfMark LU−21 LUBRICATION − OIL NOZZLE REMOVAL LU0KM−04 1. 2. REMOVE CYLINDER HEAD (See page EM−28) REMOVE TIMING CHAIN AND GEARS (See page EM−13) 3. REMOVE CRANKSHAFT (See page EM−83) 4. REMOVE OIL NOZZLES Remove the 6 check valves and oil nozzles. Torque: 25 N·m (250 kgf·cm, 18 ft·lbf) HINT: At the time of installation, align the pin of the nozzle with the pin hole of the cylinder block. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark LU−22 LUBRICATION − OIL NOZZLE INSPECTION LU0KN−01 1. INSPECT CHECK VALVES Push the valve with a wooden stick to check if it is stuck. If stuck, replace the check valve. 2. INSPECT OIL NOZZLES Check the oil nozzles for damage or clogging. If necessary, replace the oil nozzle. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark LU−23 LUBRICATION − OIL NOZZLE LU0KO−01 INSTALLATION Installation is in the reverse order of removal (See page LU−21). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark MA−1 MAINTENANCE − OUTSIDE VEHICLE OUTSIDE VEHICLE MA02P−04 GENERAL MAINTENANCE The owners are responsible for these maintenance and inspection items. They can be done by the owner or they can have them done at a service shop. These items include those which should be checked on a daily basis, those which, in most cases, do not require (special) tools and those which are considered to be reasonable for the owner to do. Items and procedures for general maintenance are as follows. 1. GENERAL NOTES S Maintenance items may vary from country to country. Check the owner’s manual supplement in which the maintenance schedule is shown. S Every service item in the periodic maintenance schedule must be performed. S Periodic maintenance service must be performed according to whichever interval in the periodic maintenance schedule occurs first, the odometer reading (miles) or the time interval (months). S Maintenance service after the last period should be performed at the same interval as before unless otherwise noted. S Failure to do even one item can cause the engine to run poorly and increase exhaust emissions. 2. TIRES (a) Check the pressure with a gauge. If necessary, adjust. (b) Check for cuts, damage or excessive wear. 3. WHEEL NUTS When checking the tires, check the nuts for looseness or for missing nuts. If necessary, tighten them. 4. TIRE ROTATION Check the owner’s manual supplement in which the maintenance schedule is shown. 5. WINDSHIELD WIPER BLADES Check for wear or cracks whenever they do not wipe clean. If necessary, replace. 6. FLUID LEAKS (a) Check underneath for leaking fuel, oil, water or other fluid. (b) If you smell gasoline fumes or notice any leak, have the cause found and corrected. 7. DOORS AND ENGINE HOOD (a) Check that all doors and the tailgate operate smoothly, and that all larches lock securely. (b) Check that the engine hood secondary latch secures the hood from opening when the primary latch is released. 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 1 Brought to you by BirfMark MA−2 MAINTENANCE − INSIDE VEHICLE INSIDE VEHICLE MA02Q−04 GENERAL MAINTENANCE The owners are responsible for these maintenance and inspection items. They can be done by the owner or they can have them done at a service shop. These items include those which should be checked on a daily basis, those which, in most cases, do not require (special) tools and those which are considered to be reasonable for the owner to do. Items and procedures for general maintenance are as follows. 1. GENERAL NOTES S Maintenance items may vary from country to country. Check the owner’s manual supplement in which the maintenance schedule is shown. S Every service item in the periodic maintenance schedule must be performed. S Periodic maintenance service must be performed according to whichever interval in the periodic maintenance schedule occurs first, the odometer reading (miles) or the time interval (months). S Maintenance service after the last period should be performed at the same interval as before unless otherwise noted. S Failure to do even one item can cause the engine to run poorly and increase exhaust emissions. 2. LIGHTS (a) Check that the headlights, stop lights, taillights, turn signal lights, and other lights are all working. (b) Check the headlights aim. 3. WARNING LIGHTS AND BUZZERS Check that all warning lights and buzzers function properly. 4. HORN Check that it is working. 5. WINDSHIELD Check for scratches, pits or abrasions. 6. WINDSHIELD WIPER AND WASHER (a) Check operation of the wipers and washer. (b) Check that the wipers do not streak. 7. WINDSHIELD DEFROSTER Check that air comes out from the defroster outlet when operating the heater or air conditioner at defroster mode. 8. REAR VIEW MIRROR Check that it is mounted securely. 9. SUN VISORS Check that they move freely and mounted securely. 10. STEELING WHEEL Check that it has the specified freeplay. Be alert for changes in steering condition, such as hard steering, excessive freeplay or strange noises. 11. SEATS (a) Check that all front seat controls such as seat adjusters, seatback recliner, etc. operate smoothly. (b) Check that all latches lock securely in any position. (c) Check that the head restraints move up and down smoothly and that the locks hold securely in any latch position. (d) For folding−down rear seat backs, check that the latches look securely. 12. SEAT BELTS (a) Check that the seat belt system such as buckles, retractors and anchors operate properly and smoothly. (b) Check that the belt webbing is not cut, frayed, worn or damaged. 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 42 Brought to you by BirfMark MA−3 MAINTENANCE − INSIDE VEHICLE 13. ACCELERATOR PEDAL Check the pedal for smooth operation and uneven pedal effort or catching. 14. BRAKE PEDAL (See page BR−6) (a) Check that pedal for smoothly operation. (b) Check that the pedal has the proper reserve distance and freeplay. (c) Check the brake booster function. 15. BRAKES At a safe place, check that the brakes do not pull to one side when applied. 16. PARKING BRAKE (See page BR−8) (a) Check that the lever has the proper travel. (b) On a safe incline, check that the vehicle is held securely with only the parking brake applied. 17. AUTOMATIC TRANSMISSION ”PARK” MECHANISM (a) Check the lock release button of the selector level for proper and smooth operation. (b) On a safe incline, check that the vehicle is held securely with the selector lever in the P position and all brakes released. 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 43 Brought to you by BirfMark MA−4 MAINTENANCE − UNDER HOOD UNDER HOOD MA02R−04 GENERAL MAINTENANCE 1. GENERAL NOTICE S Maintenance items may vary from country to country. Check the owner’s manual supplement in which the maintenance schedule is shown. S Every service item in the periodic maintenance schedule must be performed. S Periodic maintenance service must be performed according to whichever interval in the periodic maintenance schedule occurs first, the odometer reading (miles) or the time interval (months). S Maintenance service after the last period should be performed at the same interval as before unless otherwise noted. S Failure to do even one item can cause the engine to run poorly and increase exhaust emissions. 2. WINDSHIELD WASHER FLUID Check that there is sufficient fluid in the tank. 3. ENGINE COOLANT LEVEL Check that the coolant level is between the FULL and LOW lines on the see−through reservoir. 4. RADIATOR AND HOSES (a) Check that the front of the radiator is clean and not blocked with leaves, dirt or bugs. (b) Check the hoses for cracks, kinks, rot or loose connections. 5. BATTERY ELECTROLYTE 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. 6. BRAKE FLUID LEVELS Check that the brake fluid level is near the upper level line on the see−through reservoir. 7. ENGINE DRIVE BELTS Check drive belt for fraying, cracks, wear or oiliness. 8. ENGINE OIL LEVEL Check the level on the dipstick with the engine turned off. 9. POWER STEERING FLUID LEVEL (a) Check the level on the dipstick. (b) The level should be in the HOT or COLD range depending on the fluid temperature. 10. AUTOMATIC TRANSMISSION FLUID LEVEL (a) Park the vehicle on a level surface. (b) With the engine idling and the parking and foot brake applied, shift the selector into all positions from the P to L, and then shift into the P. (c) Pull out the dipstick and wipe off the fluid with a clean rag. Re−insert the dipstick fully and check that the fluid level is in the HOT range. (d) Do this check with the fluid at normal driving temperature (70 − 80°C (158 − 176°F)). HINT: Wait about 30 minutes before checking the fluid level after extended driving at high speeds in hot weather, driving in heavy traffic or with a trailer. 11. EXHAUST SYSTEM Visually inspect for cracks, holes or loose supports. If any change in the sound of the exhaust or smell of the exhaust fumes is noticed, have the cause located and corrected. 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 44 Brought to you by BirfMark MA−5 MAINTENANCE − ENGINE ENGINE MA04U−01 INSPECTION HINT: Inspect these items when the engine is cold. 1. INSPECT DRIVE BELT (See page CH−2) 2. (a) P04771 INSPECT AIR FILTER Visually check that the air cleaner element is not excessively dirty, damaged or oily. If necessary, replace the air cleaner element. (b) Clean the element with compressed air. First blow from the inside thoroughly, then blow off the outside of the element. 3. REPLACE AIR FILTER Replace the air cleaner element with a new one. 4. REPLACE SPARK PLUGS (See page IG−1) 5. REPLACE ENGINE OIL AND OIL FILTER (See page LU−2) 6. REPLACE ENGINE COOLANT (See page CO−2) 7. INSPECT CHARCOAL CANISTER (See page EC−6) 8. REPLACE GASKET IN FUEL TANK CAP (See page EC−6) 9. INSPECT FUEL LINES AND CONNECTIONS (See page EC−6) 10. INSPECT EXHAUST PIPES AND MOUNTINGS Visually inspect the pipes, hangers and connections for severe corrosion, leaks or damage. 11. ADJUST VALVE CLEARANCE (See page EM−4) 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 45 Brought to you by BirfMark MA−6 MAINTENANCE − BRAKE BRAKE MA02T−03 INSPECTION MA0055 1. INSPECT BRAKE LINE PIPES AND HOSES HINT: Check in a well lighted area. Check the entire circumference and length of the brake hoses using a mirror as required. Turn the front wheels fully right or left before checking the front brake. (a) Check all brake lines and hoses. S Check for damage. S Check for wear. S Check for deformation. S Check for cracks. S Check for corrosion. S Check for leaks. S Check for bends. S Check for twists. (b) Check all clamps for tightness and connections for leakage. (c) Check that the hoses and lines are clear of sharp edges, moving parts and the exhaust system. (d) Check that the lines installed in grommets pass through the center of the grommets. 2. INSPECT FRONT BRAKE PADS AND DISCS (See page BR−27) 3. INSPECT REAR BRAKE PADS AND DISCS (See page BR−36) 4. INSPECT PARKING BRAKE LININGS AND DRUMS (See page BR−42) 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 46 Brought to you by BirfMark MA−7 MAINTENANCE − CHASSIS CHASSIS MA04V−01 INSPECTION 1. (a) INSPECT STEERING LINKAGE Check the steering linkage for looseness or damage. S Check that the tie rod ends do not have excessive play. S Check that the boot clamps are not loose. (b) Inspect the dust cover for damage. 2. INSPECT SRS AIRBAG (Driver airbag: See page RS−9) (Front passenger airbag: See page RS−23) 3. INSPECT STEERING GEAR HOUSING OIL Check the steering gear housing for oil leakage. If leakage is found, check for cause and repair. 4. INSPECT OIL LEVEL IN AUTOMATIC TRANSMISSION (See page DI−131) 5. INSPECT OIL LEVEL IN TRANSFER AND DIFFERENTIAL (a) Transfer: Remove the filler plug and feel inside the hole with your finger. Check that the oil comes to within 5 mm (0.20 in.) of the bottom edge of the hole. If the level is low, add oil until it begins to run out of the filler hole. Oil drade: API GL−4 or GL−5 Viscosity: 75W−90 (b) P22573 Differential: Remove the filler plug and feel inside the hole with your finger. Check that the oil comes to within 5 mm (0.20 in.) of the bottom edge of the hole. If the level is low, add oil until it begins to run out of the filler hole. Oil drade: Hypoid gear oil API GL−5 Viscosity: Above −18°C (0°F) SAE 90 Below −18°C (0°F) SAE 80W−90 or 80W 6. REPLACE AUTOMATIC TRANSMISSION FLUID (See page DI−3) 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 47 Brought to you by BirfMark MA−8 MAINTENANCE 7. (a) (b) (c) Drain Plug 8. P22572 P22574 Drain Plug − CHASSIS REPLACE TRANSFER AND DIFFERENTIAL OIL Remove the drain plug and drain the oil. Reinstall the drain plug securely. Add new oil until it begins to run out of the filler hole. Oil drade and viscosity: See step 5. Oil capacity: Transfer oil 1.7 liters (1.8 US qts, 1.5 lmp. qts) Front differential oil (w/o Differential lock) 2.8 liters (3.0 US qts, 2.5 lmp. qts) Front differential oil (w/ Differential lock) 2.65 liters (2.8 US qts, 2.3 lmp. qts) Rear differential oil 3.25 liters (3.4 US qts, 2.9 lmp. qts) REPACK FRONT WHEEL BEARINGS (See pages SA−7 and SA−9) B13834 9. (a) (b) (c) LUBE STEERING KNUCKLE CHASSIS AND PROPELLER SHAFT Remove the screw plug from each steering knuckle and repack with lubricant. Steering knuckle grease: Molybdenum disulfide lithium base chassis grease (NLGI No. 2) Reinstall the 2 screw plugs. Lubricate chassis components, referring to the lubrication chart. Before pumping in grease, wipe off any mud and dust on the grease fitting. Grease grade: Lithium base chassis grease (NLGI No. 2) 1 1 2 Lubricating Positions: 1. Spider 2. Slide Yoke MA0621 B13835 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 48 Brought to you by BirfMark MA−9 MAINTENANCE − BODY BODY MA04W−01 INSPECTION 1. (a) (b) 2. (a) (b) (c) TIGHTEN BOLTS AND NUTS ON CHASSIS AND BODY Tighten the front seat−to−body mounting bolts. Torque: 39 N·m (400 kgf·cm, 29 ft·lbf) Under Severe Conditions: In addition to the above maintenance items, check for loose or missing nuts and bolts on the steering system, drive train, suspension system, fuel tank mounts, engine mounts, etc. FINAL INSPECTION Check the operation of the body parts: S Hood: Auxiliary catch operates properly Hood locks securely when closed S Front and rear doors: Door locks operate properly Doors close properly S Back door: Door lock operates properly S Seats: Seat adjusts easily and locks securely in any position Front seat back locks securely in any position Folding−down rear seat backs look securely Road test S Check the engine and chassis for abnormal noises. S Check that the vehicle does not wander or pull to one side. S Check that the brakes work properly and do not drag. Be sure to deliver a clean car. Especially check the steering wheel, shift lever knob, all switch knobs, door handles and seats. 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 49 Brought to you by BirfMark PP−1 PREPARATION − MAINTENANCE MAINTENANCE PP2ZZ−01 EQUIPMENT Mirror Brake hose Torque wrench 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 50 Brought to you by BirfMark PP−2 PREPARATION − ENGINE MECHANICAL ENGINE MECHANICAL PP300−01 SST (Special Service Tools) 09201−10000 Valve Guide Bushing Remover & Replacer Set (09201−01070) Valve Guide Bushing Remover & Replacer 7 09202−70020 (09202−00010) Valve Spring Compressor Attachment 09213−58012 Crankshaft Pulley Holding Tool 09223−15030 Oil Seal & Bearing Replacer 09236−00101 Water Pump Overhaul Tool Set (09236−15010) Bearing Stay Valve stem oil seal 09248−06020 Valve Lifter Stopper 09248−55050 Valve Clearance Adjust Tool Set (09248−05510) 09316−60011 Crankshaft rear oil seal Valve Lifter Press Transmission & Transfer Bearing Replacer 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 51 Brought to you by BirfMark PP−3 PREPARATION − ENGINE MECHANICAL (09316−00011) Replacer Pipe Crankshaft front oil seal (09316−00051) Replacer ”D” Crankshaft front oil seal 09330−00021 Companion Flange Holding Tool Crankshaft pulley 09636−20010 Upper Ball Joint Dust Cover Replacer Crankshaft timing gear 09816−30010 Oil Pressure Switch Socket Knock sensor 09843−18020 Diagnosis Check Wire 09950−40011 Puller B Set (09951−04010) Hanger 150 (09952−04010) Slide Arm (09953−04020) Center Bolt 150 (09954−04010) Arm 25 (09955−04061) Claw No.6 09950−50012 Crankshaft timing gear Puller C Set Crankshaft pulley 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 52 Brought to you by BirfMark PP−4 PREPARATION − ENGINE MECHANICAL (09951−05010) Hanger 150 (09952−05010) Slide Arm (09953−05010) Center Bolt 100 (09953−05020) Center Bolt 150 (09954−05020) Claw No.2 09950−60010 Replacer Set (09951−00280) Replacer 28 Connecting rod bushing (09951−00350) Replacer 35 Crankshaft timing gear (09951−00480) Replacer 48 Spark plug tube gasket 09950−70010 Handle Set (09951−07100) Handle 100 (09951−07150) Handle 150 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 53 Brought to you by BirfMark PP-5 PREPARATION - ENGINE MECHANICAL PP301-01 RECOMMENDED TOOLS 09082-00040 TOYOTA Electrical Tester. 09200-00010 Engine Adjust Kit . 09258-00030 Hose Plug Set . 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Plug for the vacuum hose, fuel hose etc. Brought to you by BirfMark PP-6 PREPARATION - ENGINE MECHANICAL PP302-01 EQUIPMENT Caliper gauge CO/HC meter Compression gauge Connecting rod aligner Cylinder gauge Dial indicator Dye penetrant Engine tune-up tester Heater Magnetic finger Micrometer OBD II scan tool Engine speed Piston ring compressor Piston ring expander Plastigage Precision straight edge Soft brush Spring tester Valve spring Steel square Valve spring Thermometer Torque wrench Valve seat cutter Vernier calipers 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark PP−7 PREPARATION − ENGINE MECHANICAL PP303−01 SSM (Special Service Materials) 08826−00080 Seal Packing Black or equivalent (FIPG) Over space between cylinder block and timing chain case Timing cgain cover Semi−circular plug Oil pan Rear oil seal retainer 08833−00070 Adhesive 1324, THREE BOND 1324 or equivalent Plug tube 08833−00080 Adhesive 1344 THREE BOND 1344 LOCTITE 242 or equivalent TVV 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark PP−8 PREPARATION − EMISSION CONTROL EMISSION CONTROL PP305−02 RECOMMENDED TOOLS 09082−00040 TOYOTA Electrical Tester. 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 57 Brought to you by BirfMark PP−9 PREPARATION − EMISSION CONTROL PP306−01 EQUIPMENT Heater TVV OBD II scan tool Engine speed Thermometer TVV Torque wrench Vacuum gauge 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark PP−10 PREPARATION − EMISSION CONTROL PP307−01 SSM (Special Service Materials) 08833−00070 Adhesive 1324, THREE BOND 1324 or equivalent 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 TVV Brought to you by BirfMark PP−11 PREPARATION − SFI SFI PP3KU−01 SST (Special Service Tools) 09268−41047 Injection Measuring Tool Set (09268−41091) NO.7 Union (90405−09015) No.1 Union 09268−45012 EFI Fuel Pressure Gauge 09631−22020 Power Steering Hose Nut 14 x 17 mm Wrench Set Fuel line flare nut 09816−30010 Oil Pressure Switch Socket Knock sensor 09842−30070 Wiring ”F” EFI Inspection 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 60 Brought to you by BirfMark PP−12 PREPARATION − SFI PP309−01 RECOMMENDED TOOLS 09082−00040 TOYOTA Electrical Tester. 09200−00010 Engine Adjust Kit . 09258−00030 Hose Plug Set . 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Plug for vacuum hose, fuel hose, etc. Brought to you by BirfMark PP−13 PREPARATION − SFI PP30A−01 EQUIPMENT Carburetor cleaner Throttle body Graduated cylinder Injector OBD II scan tool Engine speed Soft brush Throttle body Sound scope Injector Torque wrench 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark PP−14 PREPARATION − COOLING COOLING PP30B−01 EQUIPMENT Heater Thermostat Radiator cap tester Thermometer Thermostat Torque wrench 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 63 Brought to you by BirfMark PP−15 PREPARATION − COOLING PP30C−03 COOLANT Item Engine coolant w/ Front heater w/ Front heater and rear heaters Capacity Classification Ethylene−glycol base 12.5 liters (13.2 US qts, 11.1 lmp. qts) 13.4 liters (14.2 US qts, 11.8 lmp. qts) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark PP−16 PREPARATION − LUBRICATION LUBRICATION PP30D−04 SST (Special Service Tools) 09032−00100 Oil Pan Seal Cutter 09228−44011 Oil Filter Wrench 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 65 Brought to you by BirfMark PP−17 PREPARATION − LUBRICATION PP30E−01 RECOMMENDED TOOLS 09200−00010 Engine Adjust Kit . 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark PP−18 PREPARATION − LUBRICATION PP30F−01 EQUIPMENT Oil pressure gauge Precision straight edge Oil pump Torque wrench 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark PP−19 PREPARATION − LUBRICATION PP30G−03 LUBRICANT Item Engine oil Dry fill Drain and refill w/ Oil filter change w/o Oil filter change Capacity Classification 8.0 liters (8.5 US qts, 7.0 Imp. qts) 7.4 liters (7.8 US qts, 6.5 Imp. qts) 6.9 liters (7.3 US qts, 6.1 Imp qts) API grade SH, Energy−Conserving II multigrade engine oil or ILSAC multigrade engine oil and recommended viscosity oil, with SAE 5W−30 being preferred engine oil 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark PP−20 PREPARATION − LUBRICATION PP30H−01 SSM (Special Service Materials) 08826−00080 Seal Packing Black or equivalent (FIPG) Oil pump Oil pan (Timing chain cover) 08833−00080 Adhesive 1344 THREE BOND 1344 LOCTITE 242 or equivalent Oil pressure switch 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark PP−21 PREPARATION − IGNITION IGNITION PP30I−01 RECOMMENDED TOOLS 09082−00040 TOYOTA Electrical Tester. 09200−00010 Engine Adjust Kit . 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 70 Brought to you by BirfMark PP−22 PREPARATION − IGNITION PP30J−01 EQUIPMENT Spark plug cleaner Torque wrench 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark PP−23 PREPARATION − STARTING STARTING PP30K−03 SST (Special Service Tools) 09286−46011 Injection Pump Spline Shaft Puller Armature bearing 09810−38140 Starter Magnet Switch Nut Wrench 14 Terminal nut 09820−00030 Alternator Rear Bearing Replacer Armature rear bearing 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 72 Brought to you by BirfMark PP−24 PREPARATION − STARTING PP30L−01 RECOMMENDED TOOLS 09082−00040 TOYOTA Electrical Tester. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark PP−25 PREPARATION − STARTING PP30M−01 EQUIPMENT Dial indicator Commutator Magnetic finger Steel ball Press Magnetic switch terminal kit Pull scale Brush spring Sandpaper Commutator Torque wrench V−block Commutator Vernier calipers Commutator, Brush 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark PP−26 PREPARATION − CHARGING CHARGING PP30N−01 SST (Special Service Tools) 09285−76010 Injection Pump Camshaft Bearing Cone Replacer Rotor rear bearing cover 09286−46011 Injection Pump Spline Shaft Puller Rectifier end frame 09820−00021 Alternator Rear Bearing Puller 09820−00030 Alternator Rear Bearing Replacer 09820−63010 Alternator Pulley Set Nut Wrench Set 09950−60010 Replacer Set (09951−00260) Replacer 26 Rotor front bearing (09951−00500) Replacer 50 Rotor front bearing (09952−06010) Adapter Rotor front bearing 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 75 Brought to you by BirfMark PP−27 PREPARATION − CHARGING PP30O−01 RECOMMENDED TOOLS 09082−00040 TOYOTA Electrical Tester. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark PP−28 PREPARATION − CHARGING PP30P−01 EQUIPMENT Belt tension gauge Torque wrench Vernier calipers Rotor (Slip ring), Brush 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark PP−29 PREPARATION − AUTOMATIC TRANSMISSION AUTOMATIC TRANSMISSION PP3KT−01 SST (Special Service Tools) 09032−00100 Oil Pan Seal Cutter 09201−10000 Valve Guide Bushing Remover & Replacer Set (09201−01080) Valve Guide Bushing Remover & Replacer 8 09350−30020 TOYOTA Automatic Transmission Tool Set (09351−32010) One−way Clutch Test Tool (09351−32020) Stator Stopper 09921−00010 Spring Tension Tool 09992−00095 Automatic Transmission Oil Pressure Gauge Set Speedometer driven gear oil seal Speedometer driven gear oil seal 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 78 Brought to you by BirfMark PP−30 PREPARATION − AUTOMATIC TRANSMISSION PP3KS−01 RECOMMENDED TOOLS 09031−00030 Pin Punch . 09082−00040 TOYOTA Electrical Tester. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark PP−31 PREPARATION − AUTOMATIC TRANSMISSION PP2XS−01 EQUIPMENT Dial indicator with magnetic base Check drive plate runout OBD II scan tool Straight edge Torque converter clutch Torque wrench Vernier Calipers Torque converter clutch 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark PP−32 PREPARATION − AUTOMATIC TRANSMISSION PP2XT−02 LUBRICANT Item Automatic transmission fluid Dry fill Drain and refill Capacity Classification ATF DEXRON®II 11.0 liters (11.6 US qts, 9.7 lmp. qts) 1.9 liters (2.0 US qts, 1.7 lmp. qts) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark PP−33 PREPARATION − AUTOMATIC TRANSMISSION PP3KR−01 SSM (Special Service Materials) 08826−00090 Seal Packing 1281, THREE BOND 1281 or equivalent (FIPG) Oil pan 08833−00080 Adhesive 1344 THREE BOND 1344 LOCTITE 242 or equivalent Extension housing 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark PP−34 PREPARATION − TRANSFER TRANSFER PP3KQ−01 SST (Special Service Tools) 09223−00010 Cover & Seal Replacer Center differential 09223−15020 Oil Seal & Bearing Replacer Front extension housing 09316−12010 Transfer Bearing Replacer Center differential 09316−20011 Transfer Bearing Replacer Front extension housing Rear extension housing Component parts removal and installation 09316−60011 (09316−00011) Transmission & Transfer Bearing Replacer Replacer Pipe Front extension housing Rear extension housing Idler gear Component parts removal and installation Center differential (09316−00021) Replacer ”A” Rear extension housing (09316−00031) Replacer ”B” Front extension housing Rear extension housing Idler gear Component parts removal and installation Input shaft (09316−00041) Replacer ”C” Component parts removal and installation Front extension housing Rear extension housing (09316−00061) Replacer ”E” Front extension housing (09316−00071) Replacer ”F” Idler gear Front extension housing Transmission Oil Plug Rear extension housing 09325−12010 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 83 Brought to you by BirfMark PP−35 PREPARATION − TRANSFER 09527−30010 Rear Axle Shaft Bearing Remover Input shaft 09608−00081 Differential Side Bearing Cone Replacer Component parts removal and installation 09612−24014 Steering Gear Housing Overhaul Tool Set Center differential (09612−10050) Steering Rack Shaft Bushing Replacer 09950−00020 Bearing Remover Idler gear Center differential Front extension housing 09950−00030 Bearing Remover Attachment Center differential 09950−40011 Puller B Set Component parts removal and installation Front extension housing 09950−60010 Replacer Set (09951−00320) Replacer 32 Component parts removal and installation Center differential (09951−00400) Replacer 40 Center differential 09950−70010 Handle Set Component parts removal and installation Front extension housing Center differential (09951−07150) Handle 150 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 84 Brought to you by BirfMark PP−36 PREPARATION − TRANSFER PP2XV−01 RECOMMENDED TOOLS 09031−00030 Pin Punch . 09040−00010 Hexagon Wrench Set . 09042−00010 Torx Socket T30 . 09042−00020 Torx Socket T40 . 09082−00040 TOYOTA Electrical Tester. 09905−00012 Snap Ring No.1 Expander . 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark PP−37 PREPARATION − TRANSFER PP2XW−01 EQUIPMENT Dial indicator Feeler gauge Magnetic finger Straight edge Torque wrench Vernier calipers 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark PP−38 PREPARATION − TRANSFER PP2XX−01 LUBRICANT Item Transfer oil Capacity 1.7 liters (1.8 US qts, 1.5 lmp. qts) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Classification API GL−4 or GL−5 SAE 75W−90 Brought to you by BirfMark PP−39 PREPARATION − TRANSFER PP2XY−02 SSM (Special Service Materials) 08826−00090 Seal Packing 1281, THREE BOND 1281 or equivalent (FIPG) Front case x Rear case Rear case x Case cover Case x Extension housing 08833−00070 Adhesive 1324, THREE BOND 1324 or equivalent Dynamic damper set bolt 08833−00080 Adhesive 1344 THREE BOND 1344 LOCTITE 242 or equivalent Straight screw plug Case cover set bolt 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark PP−40 PREPARATION − PROPELLER SHAFT PROPELLER SHAFT PP2Y8−01 SST (Special Service Tools) 09332−25010 Universal Joint Bearing Remover & Replacer Spider bearing 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 89 Brought to you by BirfMark PP−41 PREPARATION − PROPELLER SHAFT PP2Y7−01 EQUIPMENT Dial indicator Torque wrench 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark PP−42 PREPARATION − SUSPENSION AND AXLE SUSPENSION AND AXLE PP3KP−01 SST (Special Service Tools) 09214−76011 Crankshaft Pulley Replacer Front differential Rear differential 09223−15020 Oil Seal & Bearing Replacer Front differential Rear axle 09226−10010 Crankshaft Front & Rear Bearing Replacer Rear suspension 09308−00010 Oil Seal Puller Front axle Front differential Rear axle Rear differential 09308−10010 Oil Seal Puller Front differential Rear differential 09315−00022 Clutch Release Bearing Remover & Replacer Rear differential 09316−20011 Transfer Bearing Replacer Rear suspension 09316−60011 Transmission & Transfer Bearing Replacer Front differential Rear differential (09316−00011) Replacer Pipe (09316−00021) Replacer ”A” (09316−00051) Replacer ”D” 09330−00021 Companion Flange Holding Tool Front differential Rear differential 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 91 Brought to you by BirfMark PP−43 PREPARATION − SUSPENSION AND AXLE 09504−00011 Differential Side Bearing Adjusting Nut Wrench Front differential Rear differential 09504−22011 Differential Side Bearing Replacer Rear differential 09506−35010 Differential Drive Pinion Rear Bearing Replacer Rear differential Rear suspension 09509−25011 Rear Axle Bearing Lock Nut Wrench Rear axle 09517−36010 Rear Axle Shaft Oil Seal Replacer− Rear axle 09550−10013 Replacer Set ”B” Rear differential Rear suspension (09553−10010) Differential Side Bearing Replacer (09557−10011) Differential Drive Pinion Front Bearing Replacer 09550−60010 Differential Side Bearing Replacer Rear differential 09556−22010 Drive Pinion Front Bearing Remover Front differential Rear differential 09605−60010 Steering Knuckle Bearing Cup Replacer− Front axle 09606−60020 Steering Knuckle Bearing Remover Front axle 09607−60020 Front Wheel Adjusting Nut Wrench Front axle 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 92 Brought to you by BirfMark PP−44 PREPARATION − SUSPENSION AND AXLE 09611−22012 Tie Rod End Puller Front axle 09612−65014 Steering Worm Bearing Puller Front axle (09612−01010) Claw ”A” (09612−01050) Hanger Pin with Nut 09618−60010 Front Axle & Drive Shaft Bearing Replacer Front axle 09710−22021 Front Suspension Bushing Tool Set Rear suspension (09710−01071) 09710−22042 Lower Arm Bushing Remover Rear Suspension Bushing Tool Set (09710−02051) Base (09710−02061) Replacer (09710−02071) Bushing Remover & Replacer Front suspension 09710−30050 Suspension Arm Bushing Replacer Front suspension 09726−40010 Lower Control Shaft Bearing Replacer Front differential Rear differential 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 93 Brought to you by BirfMark PP−45 PREPARATION − SUSPENSION AND AXLE 09727−30021 Coil Spring Compressor 09950−00020 Bearing Remover Front differential Rear differential 09950−30011 Puller A Set Front differential Rear differential (09951−03010) Upper Plate (09953−03010) Center Bolt (09954−03010) Arm (09955−03030) Lower Plate 130 (09956−03020) Adapter 18 09950−40011 Puller B Set (09951−04010) Hanger 150 (09952−04010) Slide Arm (09953−04020) Center Bolt 150 (09954−04010) Arm 25 Front differential Rear differential 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 94 Brought to you by BirfMark PP−46 PREPARATION (09955−04011) Claw No.1 (09955−04061) Claw No.6 (09957−04010) Attachment (09958−04011) Holder − 09950−60010 Replacer Set (09951−00480) Replacer 48 (09951−00490) Replacer 49 (09951−00540) Replacer 54 09950−60020 SUSPENSION AND AXLE Front differential Rear differential Rear suspension Replacer Set No.2 (09951−00710) Replacer 71 (09951−00720) Replacer 72 (09951−00810) Replacer 81 (09951−00890) Replacer 89 Front axle Rear axle Rear differential 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 95 Brought to you by BirfMark PP−47 PREPARATION − (09951−00910) Replacer 91 09950−70010 Handle Set SUSPENSION AND AXLE Front axle Front suspension Rear axle Rear differential Rear suspension (09951−07100) Handle 100 (09951−07150) Handle 150 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 96 Brought to you by BirfMark PP−48 PREPARATION − SUSPENSION AND AXLE PP3KO−01 RECOMMENDED TOOLS 09025−00010 Small Torque Wrench (30 kgf−cm) Front differential Rear differential 09031−00030 Pin Punch . Front differential 09040−00011 Hexagon Wrench Set . Front differential (09043−20060) Socket Hexagon Wrench 6. 09044−00020 Torx Socket E10 . Rear differential 09082−00050 TOYOTA Electrical Tester Set. Differential locking system 09905−00012 Snap Ring No.1 Expander . Front axle Front differential 09905−00013 Snap Ring Pliers . Front axle Front differential 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark PP−49 PREPARATION − SUSPENSION AND AXLE PP2YD−01 EQUIPMENT Dial indicator or dial indicator with magnetic base Feeler gauge Micrometer Spring tension gauge Torque wrench 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark PP−50 PREPARATION − SUSPENSION AND AXLE PP2YE−01 LUBRICANT Item Differential oil Front w/o Dfferential lock w/ Dfferential lock Rear Capacity 2.80 liters (2.9 US qts, 2.5 lmp. qts) 2.65 liters (2.8 US qts, 2.3 lmp. qts) 3.25 liters (3.4 US qts, 2.9 lmp. qts) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Classification Hypoid gear oil API GL−5 Above −18°C (0°F) SAE 90 Below −18°C (0°F) SAE 80W−90 or 80W Brought to you by BirfMark PP−51 PREPARATION − SUSPENSION AND AXLE PP2YF−02 SSM (Special Service Materials) 08826−00090 Seal Packing 1281, THREE BOND 1281 or equivalent (FIPG) Front differential Rear differential Differential locking system 08833−00080 Adhesive 1344 THREE BOND 1344 LOCTITE 242 or equivalent Front differential Rear differential Differential locking system 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark PP−52 PREPARATION − BRAKE BRAKE PP3KN−01 SST (Special Service Tools) 09023−00100 Union Nut Wrench 10 mm 09709−29018 LSPV Gauge Set 09717−20010 Brake Shoe Return Spring Remover 09718−20010 Brake Shoe Return Spring Replacer 09737−00010 Brake Booster Push Rod Gauge 09751−36011 Brake Line Union Nut 10 x 12 mm Wrench 09843−18020 Diagnosis Check Wire 09990−00150 ABS Actuator Checker and Sub−harness 09990−00200 ABS Actuator Checker Sub−harness ”C” 09990−00210 ABS Actuator Checker Sub−harness ”E” 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 101 Brought to you by BirfMark PP−53 PREPARATION − BRAKE PP2YH−01 RECOMMENDED TOOLS 09082−00040 TOYOTA Electrical Tester. 09905−00013 Snap Ring Pliers . 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark PP−54 PREPARATION − BRAKE PP2YI−01 EQUIPMENT Dial indicator Brake disc Micrometer Brake disc Torque wrench Vernier calipers Brake disc 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark PP−55 PREPARATION − BRAKE PP2YJ−01 LUBRICANT Item Brake fluid Capacity − 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Classification SAE J1703 or FMVSS No. 116 DOT 3 Brought to you by BirfMark PP−56 PREPARATION − STEERING STEERING PP3KM−01 SST (Special Service Tools) 09527−10011 Rear Axle Shaft Bearing Remover PS vane pump 09610−55012 Pitman Arm Puller Steering linkage 09611−22012 Tie Rod End Puller Steering linkage 09616−00011 Steering Worm Bearing Adjusting Socket PS gear 09628−62011 Ball Joint Puller Steering linkage 09630−00014 Power Steering Gear Housing Overhaul Tool Set (09631−00051) No.3 Wrench PS gear (09631−00121) Teflon Ring Former PS gear (09631−00142) Overhaul Stand PS gear 09631−10030 Oil Seal Remover PS vane pump 09631−22020 Power Steering Hose Nut 14 x 17 mm Wrench Set PS gear 09640−10010 Power Steering Pressure Gauge Set 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 105 Brought to you by BirfMark PP−57 PREPARATION − STEERING (09641−01010) Gauge Assy On−vehicle inspection (09641−01030) Attachment B On−vehicle inspection (09641−01060) Attachment E On−vehicle inspection 09910−00015 Puller Set (09911−00011) Puller Clamp Tilt steering column (09912−00010) Puller Slide Hammer Tilt steering column 09950−40011 Puller B Set (09957−04010) Attachment Tilt steering column (09958−04011) Holder Tilt steering column 09950−50010 Puller C Set (09951−05010) Hanger 150 Tilt steering column (09952−05010) Slide Arm Tilt steering column (09953−05020) Center Bolt 150 Tilt steering column 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 106 Brought to you by BirfMark PP−58 PREPARATION (09954−05020) − STEERING Claw No.2 Tilt steering column 09950−60010 Replacer Set (09951−00360) Replacer 36 PS gear (09951−00410) Replacer 41 PS gear (09952−06010) Adapter PS gear 09950−70010 Handle Set (09951−07200) Handle 200 PS gear 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 107 Brought to you by BirfMark PP−59 PREPARATION − STEERING PP3KL−01 RECOMMENDED TOOLS 09025−00010 Torque Wrench (30 kgf−cm) PS vane pump PS gear 09042−00010 Torx Socket T30 . Tilt steering column 09904−00010 Expander Set . (09904−00050) No. 4 Claw 09905−00012 Snap Ring No.1 Expander . 09905−00013 Snap Ring Pliers . 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark PP−60 PREPARATION − STEERING PP2YM−01 EQUIPMENT Caliper gauge PS vane pump Calipers PS vane pump Dial indicator PS gear Feeler gauge PS vane pump Micrometer PS vane pump Torque wrench 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark PP−61 PREPARATION − STEERING PP2YN−01 LUBRICANT Item Power steering fluid Capacity Total 0.8 liters (0.9 US qts, 0.7 lmp. qts) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Classification ATF DEXRON®II or III Brought to you by BirfMark PP−62 PREPARATION − SUPPLEMENTAL RESTRAINT SYSTEM SUPPLEMENTAL RESTRAINT SYSTEM PP2YO−02 SST (Special Service Tools) 09082−00700 SRS Airbag Deployment Tool 09843−18020 Diagnosis Check Wire 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 111 Brought to you by BirfMark PP−63 PREPARATION − SUPPLEMENTAL RESTRAINT SYSTEM PP2YP−02 RECOMMENDED TOOLS 09042−00020 Torx Socket T40 . 09082−00040 TOYOTA Electrical Tester. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Airbag sensor assembly Brought to you by BirfMark PP−64 PREPARATION − SUPPLEMENTAL RESTRAINT SYSTEM PP2YQ−02 EQUIPMENT Bolt Length: 35 mm (1.38 in.) Pitch: 1.0 mm (0.039 in.) Diam: 6.0 mm (0.236 in.) Airbag disposal Rope (no projections, difficult to break) Airbag disposal Tire Width: 185 mm (7.28 in.) Inner diam: 360 mm (14.17 in.) Airbag disposal Tire with disc wheel Width: 185 mm (7.28 in.) Inner diam: 360 mm (14.17 in.) Airbag disposal Torque wrench Steering wheel pad Vinyl bag Airbag disposal 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark PP−65 PREPARATION − BODY ELECTRICAL BODY ELECTRICAL PP2YS−02 RECOMMENDED TOOLS 09082−00040 TOYOTA Electrical Tester. 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 114 Brought to you by BirfMark PP−66 PREPARATION − BODY ELECTRICAL PP2YT−01 EQUIPMENT Bulb (3.4 W) Fuel sender gauge Seat belt warning relay Bulb (21 W) Turn signal flasher relay Clip remover For removing cowl louver Dry cell battery Fuel sender gauge Masking tape Rear window defogger wire Oil bath Engine oil level warning switch Test lead Thermometer Engine coolant temperature sender gauge Engine oil level warning switch Tin foil Rear window defogger wire Torque wrench 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark PP−67 PREPARATION − BODY ELECTRICAL PP3KK−01 SSM (Special Service Materials) 08833−00070 Adhesive 1324, THREE BOND 1324 or equivalent Power seat housing set nut Power seat slide and vertical motor set screw 08833−00080 Adhesive 1344 THREE BOND 1344 LOCTITE 242 or equivalent Low oil pressure warning switch Engine coolant temperature sender gauge 08888−88888 DuPont Paste No. 4817 or equivalent Rear window defogger 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark PP−68 PREPARATION − BODY BODY PP2YV−01 SST (Special Service Tools) 09806−30010 Windshield Moulding Remover 09812−00010 Door Hinge Set Bolt Wrench 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 117 Brought to you by BirfMark PP−69 PREPARATION − BODY PP2YW−01 LUBRICANT Item MP grease Capacity Classification − − 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark PP−70 PREPARATION − BODY PP2YX−02 SSM (Special Service Materials) 08833−00030 Three cement black or equivalent Back door glass 08833−00070 Adhesive 1324, THREE BOND 1324 or equivalent Front door Rear door Power seat regulator 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark PP−71 PREPARATION − AIR CONDITIONING AIR CONDITIONING PP3KJ−01 SST (Special Service Tools) 07110−58060 Air Conditioner Service Tool Set (07117−58060) Refrigerant Drain Service Valve (07117−58070) T−Joint (07117−58080) Quick Disconnect Adapter Discharge (Diam.: 16 mm) (07117−58090) Quick Disconnect Adapter Suction (Diam.: 13 mm) (07117−78050) Refrigerant Charging Gauge (07117−88060) Refrigerant Charging Hose Discharge (Color: Red) (07117−88070) Refrigerant Charging Hose Suction (Color: Blue) (07117−88080) Refrigerant Charging Hose Utility (Color: Green) 07112−66040 Magnetic Clutch Remover 07112−76060 Magnetic Clutch Stopper 07114−84010 Snap Ring Pliers 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 120 Brought to you by BirfMark PP−72 PREPARATION − AIR CONDITIONING 07114−84020 Snap Ring Pliers 07116−38360 Gas Leak Detector Assembly 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 121 Brought to you by BirfMark PP−73 PREPARATION − AIR CONDITIONING PP2YZ−01 RECOMMENDED TOOLS 09082−00040 TOYOTA Electrical Tester. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark PP−74 PREPARATION − AIR CONDITIONING PP2Z1−01 LUBRICANT Item Compressor oil When replacing receiver When replacing condenser When replacing evaporator When replacing compressor Capacity Classification ND−OIL 8 or equivalent 10 cc (0.35 fl.oz.) 40 cc (1.4 fl.oz.) 40 cc (1.4 fl.oz.) 120 cc (4.1 fl.oz.) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark PR−1 PROPELLER SHAFT − TROUBLESHOOTING TROUBLESHOOTING PR06N−01 PROBLEM SYMPTOMS TABLE Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely cause of the problem. Check each part in order. If necessary, replace these parts. Symptom Suspect Area See page Noise 3. Seeve yoke spline: worn 4. Spider bearing: worn or stuck PR−4 PR−4 Vibration 1. Sleeve yoke spline: stuck 2. Propeller shaft: runout 3. Propeller shaft: imbalance PR−4 PR−4 − 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 849 Brought to you by BirfMark PR−2 PROPELLER SHAFT − PROPELLER SHAFT ASSEMBLY PROPELLER SHAFT ASSEMBLY PR06O−02 COMPONENTS Front Propeller Shaft 74 (750, 54) Grease Fitting 74 (750, 54) Propeller Shaft z Snap Ring z Spider z Spider Bearing Grease Fitting Dust Cover Grease Fitting Flange Yoke Flange Yoke 74 (750, 54) Sleeve Yoke z Spider 74 (750, 54) z Snap Ring 74 (750, 54) z Spider Bearing Rear propeller Shaft 88 (900, 65) Grease Fitting z Snap Ring Propeller Shaft z Spider 88 (900, 65) z Spider Bearing Grease Fitting Dust Cover Flange Yoke Grease Fitting Flange Yoke 88 (900, 65) Sleeve Yoke z Spider z Snap Ring 88 (900, 65) N·m (kgf·cm, ft·lbf) : Specified torque z Non−reusable part z Spider Bearing Q10862 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 850 Brought to you by BirfMark PR−3 PROPELLER SHAFT PROPELLER SHAFT ASSEMBLY REMOVAL Front Propeller Shaft 1. (a) Matchmarks (b) (c) Transfer Z09285 (d) (e) 2. (a) Rear Propeller Shaft (b) (c) Transfer − Matchmarks (d) Z09286 (e) PR06P−01 REMOVE FRONT PROPELLER SHAFT Place matchmarks on the propeller shaft flange and transfer. Remove the 4 nuts and washers. Torque: 74 N·m (750 kgf·cm, 54 ft·lbf) Place matchmarks on the propeller shaft flange and differential. Remove the 4 nuts, bolts and washers. Torque: 74 N·m (750 kgf·cm, 54 ft·lbf) Remove the front propeller shaft. REMOVE REAR PROPELLER SHAFT Place matchmarks on the propeller shaft flange and transfer. Remove the 4 nuts and washers. Torque: 88 N·m (900 kgf·cm, 65 ft·lbf) Place matchmarks on the propeller shaft flange and differential. Remove the 4 nuts, bolts and washers. Torque: 88 N·m (900 kgf·cm, 65 ft·lbf) Remove the rear propeller shaft. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark PR−4 PROPELLER SHAFT − PROPELLER SHAFT ASSEMBLY INSPECTION PR06Q−01 1. INSPECT FRONT AND REAR PROPELLER SHAFTS FOR DAMAGE OR RUNOUT Using a dial indicator, check the runout of shafts. Maximum runout: 0.8 mm (0.031 in.) If shaft runout is greater than maximum, replace the shaft. PR0310 2. REMOVE SLEEVE YOKE FROM PROPELLER SHAFT Place matchmarks on the sleeve yoke and shaft. (1) Pull out the sleeve yoke from the shaft. (2) Remove the dust cover from the shaft. Matchmarks PR0014 3. INSPECT SPIDER BEARING Check the spider bearings for wear or damage. Check the spider bearing axial play by turning the yoke with holding the shaft tightly. Bearing axial play: Maximum 0.05 mm (0.0020 in.) If necessary, replace the spider bearing. 4. INSERT SLEEVE YOKE INTO PROPELLER SHAFT (a) Apply MP grease to the propeller shaft spline and sleeve yoke sliding surface. (b) Align the matchmarks on the sleeve yoke propeller shaft. (c) Install the propeller shaft into the sleeve yoke. S S PR0056 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark PR−5 PROPELLER SHAFT − PROPELLER SHAFT ASSEMBLY PR06R−01 INSTALLATION Installation is in the reverse order of removal (See page PR−3). HINT: After installation, pump MP grease into each fitting with a grease gun until the grease begins to flow around the oil seal. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark PR−6 PROPELLER SHAFT − SPIDER BEARING SPIDER BEARING Matchmarks PR06S−03 REPLACEMENT NOTICE: Be careful not to grip the propeller shaft tube too tightly in the vise as this will cause deformation. 1. REMOVE PROPELLER SHAFT (See page PR−3) 2. PLACE MATCHMARKS ON SHAFT AND YOKE PR0058 3. (a) (b) REMOVE SNAP RINGS Using a brass bar and hammer, slightly tap in the bearing outer races. Using 2 screwdrivers, remove the 4 snap rings from the grooves. Z00753 4. (a) REMOVE SPIDER BEARINGS Using SST, push out the bearing from the flange. SST 09332−25010 HINT: Sufficiently raise the part indicated by A so that it does not come into contact with the bearing. SST A PR0060 (b) Clamp the bearing outer race in a vise and tap off the flange with a hammer. HINT: Remove the bearing on the opposite side by the same procedure. PR0061 (c) (d) (e) SST Install the 2 removed bearing outer races to the spider. Using SST, push out the bearing from the yoke. SST 09332−25010 Clamp the outer bearing race in a vise and tap off the yoke with a hammer. HINT: Remove the bearing on the opposite side in the same procedure. Z00754 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 854 Brought to you by BirfMark PR−7 PROPELLER SHAFT − SPIDER BEARING 5. SELECT SPIDER BEARING Select the bearing according to whether or not there is a drill mark on the yoke section. Color Drit Mark Yoke Drit Mark Yoke Bearing (Type A) Bearing (Type B) w/ drill mark w/ color mark (White) w/ color mark (Red) No drill mark No color mark No color mark Bearing Cup Z04247 Type A 610.0 mm (24.016 in.) Y Type B Differential X Side HINT: At time of the reassemble, there are 2 types of rear propeller shafts, type A and type B. Referring to the illustration, measure the distance between the welding points X and Y to identify which of the 2 types is used for the vehicle. 545.0 mm (21.457 in.) Y X Q07142 6. INSTALL SPIDER BEARING (a) Apply MP grease to a new spider and bearings. NOTICE: Be careful not to apply too much grease. (b) Align the matchmarks on the yoke and flange. Z00755 (c) (d) Fit the spider into the yoke. Using SST, install the bearings on the spider. SST 09332−25010 (e) Using SST, adjust both bearings so that the snap ring grooves are at maximum and equal widths. PR0081 Q07338 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 855 Brought to you by BirfMark PR−8 PROPELLER SHAFT 7. (a) − SPIDER BEARING INSTALL SNAP RINGS Install 2 new snap rings of equal thickness which will allow 0 − 0.05 mm (0 − 0.0020 in.) axial play. HINT: Do not reuse the snap rings. Thickness of snap ring: Front Propeller Shaft and Rear Propeller Shaft (Type B) PR0069 Color Mark Thickness mm (in.) − 1 2.100 − 2.150 (0.0827 − 0.0846) − 2 2.150 − 2.200 (0.0846 − 0.0866) − 3 2.200 − 2.250 (0.0866 − 0.0886) Brown − 2.250 − 2.300 (0.0886 − 0.0906) Blue − 2.300 − 2.350 (0.0906 − 0.0925) − 6 2.350 − 2.400 (0.0925 − 0.0945) − 7 2.400 − 2.450 (0.0945 − 0.0965) − 8 2.450 − 2.500 (0.0965 − 0.0984) Rear Propeller Shaft (Type A) Color Thickness mm (in.) − 2.00 (0.0787) Brown 2.03 (0.0799) Blue 2.06 (0.0811) − 2.09 (0.0823) (b) Using a hammer, tap the yoke until there is no clearance between the bearing outer race and snap ring. 8. CHECK SPIDER BEARING (See page PR−4) Check that the spider bearing moves smoothly. Check the spider bearing axial play. Bearing axial play: Maximum 0.05 mm (0.0020 in.) S S HINT: S S PR0031 Install a new spider bearing on the flange side in the procedure described above. When replacing the spider bearing, be sure that the grease fitting assembly hole is facing in the direction shown in the illustration. 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 856 Brought to you by BirfMark PR−9 PROPELLER SHAFT − SPIDER BEARING SPIDER GREASE FITTING ASSEMBLY DIRECTION Front Propeller Shaft The Figure at left shows the locations of the grease fittings as seen from the rear. Sleeve Yoke No.1 No.1 No.2 Sleeve Yoke No.2 SPIDER GREASE FITTING ASSEMBLY DIRECTION Rear Propeller Shaft No.2 The Figure at left shows the locations of the grease fittings as seen from the rear. Sleeve Yoke No.1 No.1 No.2 Sleeve Yoke Q09100 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 857 Brought to you by BirfMark RS−1 SUPPLEMENTAL RESTRAINT SYSTEM − SRS AIRBAG SRS AIRBAG RS0OZ−02 PRECAUTION NOTICE: S The LAND CRUISER is equipped with an SRS , which comprises a driver airbag and a front passenger airbag. Failure to carry out service operations in the correct sequence could cause the SRS to unexpectedly deploy during servicing, possibly leading to a serious accident. Further, if a mistake is made in servicing the SRS, it is possible the SRS may fail to operate when required. Before performing servicing (including removal or installation of parts, inspection or replacement), be sure to read the following items carefully, then follow the correct procedure described in the repair manual. S Malfunction symptoms of the SRS are difficult to confirm, so the DTCs become the most important source of information when troubleshooting. When troubleshooting the SRS, always inspect the DTCs before disconnecting the battery. S Even in cases of a minor collision where the SRS does not deploy, the steering wheel pad, front passenger airbag assembly, and airbag sensor assembly should be inspected (See pages RS−9, RS−23 and RS−34) S Never use SRS parts from another vehicle. When replacing parts, replace them with new parts. S Never disassemble and repair the steering wheel pad, front passenger airbag assembly, or airbag sensor assembly in order to reuse it. S If the steering wheel pad, front passenger airbag assembly or airbag sensor assembly have been dropped, or if there are cracks, dents or other defects in the case, bracket or connector, replace them with new ones. S Use a volt/ohmmeter with high impedance (10 kΩ/V minimum) for troubleshooting the system’s electrical circuits. S Information labels are attached to the periphery of the SRS components. Follow the instructions on the notices. S After work on the SRS is completed, check the SRS warning light (See page DI−240). S If the vehicle is equipped with a mobile communication system, refer to the precaution in the IN section. CAUTION: S Work must be started after 90 seconds from the time the ignition switch is turned to the ”LOCK” position and the negative (−) terminal cable is disconnected from the battery. (The SRS is equipped with a back−up power source so that if work is started within 90 seconds of disconnecting the negative (−) terminal cable of the battery, the SRS may be deployed.) S When the negative (−) terminal cable is disconnected from the battery, the memory of the clock and audio system will be canceled. So before starting work, make a record of the contents memorized in the audio memory system. When work is finished, reset the audio systems as they were before and adjust the clock. To avoid erasing the memory of each memory system, never use a back−up power supply from outside the vehicle. S Before repairs, remove the airbag sensor if shocks are likely to be applied to the sensor during repairs. S Do not expose the steering wheel pad, front passenger airbag assembly, or airbag sensor assembly directly to hot air or flames. 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 1100 Brought to you by BirfMark RS−2 SUPPLEMENTAL RESTRAINT SYSTEM − SRS AIRBAG OPERATION RS0P0−01 1. STEERING WHEEL PAD (with AIRBAG) The inflater and bag of the SRS are stored in the steering wheel pad and cannot be disassembled. The inflater contains a squib, igniter charge, gas generant, etc., and inflates the bag when instructed by the airbag sensor assembly. 2. SPIRAL CABLE (in COMBINATION SWITCH) A spiral cable is used as an electrical joint from the vehicle body side to the steering wheel. Spiral Cable AB0250 3. FRONT PASSENGER AIRBAG ASSEMBLY The inflater and bag of the SRS are stored in the front passenger airbag assembly and cannot be disassembled.The inflater contains a squib, igniter charge, gas generant, etc., and inflates the bag when instructed by the airbag sensor assembly. 4. SRS WARNING LIGHT The SRS warning light is located on the combination meter. It goes on to alert the driver of trouble in the system when a malfunction is detected in the airbag sensor assembly. In normal operating condition when the ignition switch is turned to the ACC or ON position, the light goes on for about 6 seconds and then goes off. R13451 5. AIRBAG SENSOR ASSEMBLY The airbag sensor assembly is mounted on the floor inside the console box. The airbag sensor assembly consists of an airbag sensor, safing sensor, diagnosis circuit and ignition control, drive circuit, etc. It receives signals from the airbag sensors and judges whether the SRS must be activated or not. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark RS−3 SUPPLEMENTAL RESTRAINT SYSTEM 6. − SRS AIRBAG SRS CONNECTORS Front Passenger Airbag Assembly Spiral Cable Steering Wheel Pad Airbag Sensor Assembly Instrument Panel Junction Block Junction Block No. 1 R11937 No. Item Application (1) Terminal Twin−Lock Mechanism (2) Airbag Activation Prevention Mechanism Connectors 2, 3, 4 (3) Electrical Connection Check Mechanism Connectors 1 (4) Connector Twin−Lock Mechanism (a) Connectors 1, 2, 3, 4, 5, 6, 7 Connectors 2, 3, 4 All connectors in the SRS are colored yellow to distinguish them from other connectors. Connectors having special functions and specifically designed for the SRS are used in the locations shown above to ensure high reliability. These connectors use durable gold−plated terminals. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark RS−4 SUPPLEMENTAL RESTRAINT SYSTEM (1) Spacer Housing (2) Female Male Z05953 − SRS AIRBAG Terminal Twin−Lock Mechanism Each connector has a two−piece construction consisting of a housing and a spacer. This design secures the locking of the terminal by two locking devices (the retainer and the lance) to prevent terminals from coming out. Airbag Activation Prevention Mechanism Each connector contains a short spring plate. When the connector is disconnected, the short spring plate automatically connects the power source and grounding terminals of the squib. F When Connector is Connected F When Connector is Disconnected Short Spring Plate Short Spring Plate Contacting Male Terninal Housing Housing Short Spring Plate ON Terminal Squib Connectors Squib Short Spring Plate Closed Circuit R10587 HINT: The type of connector shown above is used for connectors 2, 3 and 4 in the diagram on the preceding page. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark RS−5 SUPPLEMENTAL RESTRAINT SYSTEM − (3) SRS AIRBAG Electrical Connection Check Mechanism This mechanism electrically checks if connectors are connected correctly and completely. The electrical connection check mechanism is designed so that the disconnection detection pin connects with the diagnosis terminals when the connector housing lock is locked. F Comlate Connection F Half Connection Terminal of Diagnosis Disconnection Detection Pin Terminal of Diagnosis R13061 HINT: The illustration shows connector 1. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark RS−6 SUPPLEMENTAL RESTRAINT SYSTEM (4) − SRS AIRBAG Connector Twin−Lock Mechanism With this mechanism connectors (male and female connectors) are locked by 2 locking devices to increase connection reliability. If the primary lock is incomplete, ribs interfere and prevent the secondary lock. Secondary Lock Lock Primary Lock Primary Lock Complate (Secondary Lock Permitted Primary Lock Incomplate (Secondary Lock Prevended) Lock Twin−Lock Complated Z05490 (b) Fig.1 Power Source Safing Sensor Fig.2 Squibs Airbag Sensor When the vehicle is involved in a frontal collision in the hatched area (Fig. 1) and the shock is larger than the predetermined level, the SRS is activated automatically. A safing sensor is designed to go on at a smaller deceleration rate than the airbag sensor. As illustrated in Fig. 2, ignition is caused when current flows to the squib, which happens when a safing sensor and the airbag sensor go on simultaneously.When a deceleration force acts on the sensors, two squibs in the driver airbag and front passenger airbag ignite and generate gas. The gas discharging into the driver airbag and front passenger airbag rapidly increases the pressure inside the bags, breaking open the steering wheel pad and instrument panel door. Bag inflation then ends, and the bags deflate as the gas is discharged through discharge holes at the bag’s rear or side. Z14034 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark RS−7 SUPPLEMENTAL RESTRAINT SYSTEM − STEERING WHEEL PAD AND SPIRAL CABLE STEERING WHEEL PAD AND SPIRAL CABLE RS0P1−01 COMPONENTS 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 1106 Brought to you by BirfMark RS−8 SUPPLEMENTAL RESTRAINT SYSTEM − STEERING WHEEL PAD AND SPIRAL CABLE RS0P2−01 REMOVAL REMOVE STEERING WHEEL AND SPIRAL CABLE (See page SR−11) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark RS−9 SUPPLEMENTAL RESTRAINT SYSTEM − STEERING WHEEL PAD AND SPIRAL CABLE INSPECTION RS0P3−01 1. (a) (b) VEHICLES NOT INVOLVED IN A COLLISION Do a diagnostic system check (See page DI−240). With the steering wheel pad (with airbag) installed in the vehicle, do a visual check with includes the following items. Check for cuts, minute cracks or marked discoloration of the steering wheel pad top surface and grooved portion. 2. (a) (b) VEHICLES INVOLVED IN A COLLISION Do a diagnostic system check (See page DI−240). Do a visual check. With the steering wheel pad removed from the vehicle, do a visual check with includes the following items. S Check for cuts and cracks in, or marked discoloration of, the steering wheel pad top surface and its grooved portion. S Check for cuts and cracks in wire harnesses, and for chipping in connectors. S Check for deformation of the horn button contact plate of the steering wheel. HINT: Horn Bottom Contact Plate S If the horn button contact plate of the steering wheel is deformed, never repair it. Always replace the steering wheel assembly with a new one. R12685 There should be no interference between the steering wheel pad and the steering wheel, and the clearance should be uniform all the way around when the new steering wheel pad is installed on the steering wheel. CAUTION: For removal and installation of the steering wheel pad, see pages SR−11 and SR−19 and be sure to follow the correct procedure. S 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark RS−10 SUPPLEMENTAL RESTRAINT SYSTEM − STEERING WHEEL PAD AND SPIRAL CABLE 3. VEHICLE INVOLVED IN COLLISION AND AIRBAG IS DEPLOYED Do a visual check with includes the following items with the steering wheel pad removed from the vehicle. S Check for deformation of the horn button contact plate of the steering wheel. S Check for damage to the spiral cable connector and wire harness. HINT: There should be no interference between the steering wheel pad and the steering wheel, and the clearance should be uniform all the way around when the new steering wheel pad is installed on the steering wheel. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark RS−11 SUPPLEMENTAL RESTRAINT SYSTEM − STEERING WHEEL PAD AND SPIRAL CABLE DISPOSAL RS0P5−01 HINT: When scrapping vehicle equipped with an SRS or disposing of a steering wheel pad (with airbag), always first deploy the airbag in accordance with the procedure described below. If any abnormality occurs with the airbag deployment, contact the SERVICE DEPT. of the TOYOTA MOTOR SALES, U.S.A., INC. When disposing of a steering wheel pad with an airbag deployed in a collision, follow the same procedure given in step 1−(d) in ”DISPOSAL”. CAUTION: S Never dispose of a steering wheel pad which has an undeployed airbag. S The airbag produces a sizeable exploding sound when it deploys, so perform the operation out of doors and where it will not create a nuisance to nearby residents. S SST S S AB0152 S S S When deploying the airbag, always use the specified SST (SRS Airbag Deployment Tool). Perform the operation in a place away from electrical noise. SST 09082−00700 When deploying an airbag, perform the operation at least 10 m (33 ft) away from the steering wheel pad. The steering wheel pad is very hot when the airbag is deployed, so leave it alone for at least 30 minutes after deployment. Use gloves and safety glasses when handling a steering wheel pad with the deployed airbag. Always wash your hands with water after completing the operation. Do not apply water, etc. to a steering wheel pad with the deployed airbag. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark RS−12 SUPPLEMENTAL RESTRAINT SYSTEM 1. Battery − STEERING WHEEL PAD AND SPIRAL CABLE AIRBAG DEPLOYMENT WHEN SCRAPPING VEHICLE HINT: Have a battery ready as the power source to deploy the airbag. SST AB0158 (a) Check functioning of the SST. CAUTION: When deploying the airbag, always use the specified SST: SRS Airbag Deployment Tool. SST 09082−00700 SST AB0152 (1) Battery Connect the SST to the battery. Connect the red clip of the SST to the battery positive (+) terminal and the black clip to the battery negative (−) terminal. HINT: Do not connect the yellow connector which will be connected with the supplemental restraint system. SST AB0158 (2) SST H01580 Check functioning of the SST. Press the SST activation switch, and check that the LED of the SST activation switch lights up. CAUTION: If the LED lights up when the activation switch is not being pressed, SST malfunction is probable, so definitely do not use the SST. (b) Install the SST. CAUTION: Check that there is no looseness in the steering wheel and steering wheel pad. (1) Remove the steering column lower cover. Remove the 3 screws and steering column lower cover as shown in the illustration. (2) Disconnect the airbag connector of the spiral cable. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark RS−13 SUPPLEMENTAL RESTRAINT SYSTEM − STEERING WHEEL PAD AND SPIRAL CABLE (3) Connect the SST connector to the airbag connector of the spiral cable. SST 09082−00700 SST (4) Move the SST at least 10 m (33 ft) away from the front of the vehicle. Close all the doors and windows of the vehicle. (5) NOTICE: Take care not to damage the SST wire harness. (6) Connect the SST red clip to the battery positive (+) terminal and the black clip to the negative (−) terminal. 10 m (33 ft) or more R13455 (c) H02457 Deploy the airbag. (1) Confirm that no one is inside the vehicle or within 10 m (33 ft) area around the vehicle. (2) Press the SST activation switch and deploy the airbag. HINT: The airbag deploys simultaneously as the LED of the SST activation switch lights up. (d) Dispose of steering wheel pad (with airbag). CAUTION: S The steering wheel pad is very hot when the airbag is deployed, so leave it alone for at least 30 minutes after deployment. S Use gloves and safety glasses when handling a steering wheel pad with the deployed airbag. S Always wash your hands with water after completing the operation. S Do not apply water, etc. to a steering wheel pad with the deployed airbag. (1) When scrapping a vehicle, deploy the airbag and scrap the vehicle with the steering wheel pad still installed. (2) When moving a vehicle for scrapping which has a steering wheel pad with deployed airbag, use gloves and safety glasses. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark RS−14 SUPPLEMENTAL RESTRAINT SYSTEM − STEERING WHEEL PAD AND SPIRAL CABLE 2. DEPLOYMENT WHEN DISPOSING OF STEERING WHEEL PAD ONLY NOTICE: S When disposing of the steering wheel pad (with airbag) only, never use the customers vehicle to deploy the airbag. S Be sure to follow the procedure given below when deploying the airbag. HINT: Have a battery ready as the power source to deploy the airbag. (a) Remove the steering wheel pad (See page SR−11). CAUTION: When storing the steering wheel pad, keep the upper surface of the pad facing upward. (b) Remove the connector on the rear surface of the steering wheel pad from the bracket. (c) Using a service−purpose wire harness, tie down the steering wheel pad to the disc wheel. Wire harness: Stripped wire harness section 1.25 mm2 or more (0.0019 in2 or more). Connector Wire Harness Diameter Stripped Wire Harness Section AB0163 HINT: To calculate the square of the stripped wire harness section: Square = 3.14 x (Diameter)2 divided by 4 CAUTION: If a wire harness which is too thin or some other thing is used to tie down the steering wheel pad, it may be snapped by the shock when the airbag is deployed. This is highly dangerous. Always use a wire harness for vehicle use which is at least 1.25 mm2 (0.0019 in2). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark RS−15 SUPPLEMENTAL RESTRAINT SYSTEM − (1) L M R05748 STEERING WHEEL PAD AND SPIRAL CABLE Install the 2 bolts with washers in the 2 bolt holes in the steering wheel pad. Bolt: L: 35. mm (1.387 in.) M: 6.0 mm (0.236 in.) Pitch: 1.0 mm (0.039 in.) NOTICE: S Tighten the bolts by hand until the bolts become difficult to turn. S Do not tighten the bolts too much. (2) Using 3 wire harnesses, wind the wire harness at least 2 times each around the bolts installed on the left and right sides of the steering wheel pad. CAUTION: S Tightly wind the wire harness around the bolts so that there is no slack. S If there is slack in the wire harness, the steering wheel pad may come loose due to the shock when the airbag is deployed. This is highly dangerous. 2 Times or more R05749 (3) R05751 Face the upper surface of the steering wheel pad upward. Separately tie the left and right sides of the steering wheel pad to the disc wheel through the hub nut holes. Position the steering wheel pad connector so that it hangs downward through a hub hole in the disc wheel. CAUTION: S Make sure that the wire harness is tight. It is very dangerous when looseness in the wire harness results in the steering wheel pad coming free through the shock from the airbag deploying. S Always tie down the steering wheel pad with the pad side facing upward. It is very dangerous if the steering wheel pad is tied down with the metal surface facing upward as the wire harness will be cut by the shock from the airbag deploying and the steering wheel pad will be thrown into the air. NOTICE: The disc wheel will be marked by airbag deployment, so when disposing of the airbag use a redundant disc wheel. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark RS−16 SUPPLEMENTAL RESTRAINT SYSTEM (d) Battery − STEERING WHEEL PAD AND SPIRAL CABLE Check functioning of the SST. SST 09082−00700 SST AB0158 SST R05752 (e) Install the SST. CAUTION: Place the disc wheel on the level ground. (1) Connect the connector of 2 SST to the steering wheel pad connector. SST 09082−00700, 09082−00760 NOTICE: To avoid damaging the SST connector and wire harness, do not lock the secondary lock of the twin lock. Also, secure some slack for the SST wire harness inside the disc wheel. (2) Move the SST to at least 10 m (33 ft) away from the steering wheel pad tied down on the disc wheel. 10 m (33 ft) or more R13763 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark RS−17 SUPPLEMENTAL RESTRAINT SYSTEM − STEERING WHEEL PAD AND SPIRAL CABLE (f) Weight R11852 Cover the steering wheel pad with a cardboard box or tires. S Covering method using a cardboard box: Cover the steering wheel pad with the cardboard box and weight the cardboard box down in 4 places with at least 190 N (20 kg, 44 lb). Size of cardboard box: Must exceed the following dimensions: x=460 mm (18.11 in.) When dimension of the cardboard box exceeds the diameter of the disc wheel with tire to which the steering wheel pad is tied x=460 mm (18.11 in.) + width of tire y= 650 mm (25.59 in.) NOTICE: If a cardboard box smaller than the specified size is used, the cardboard box will be broken by the shock from the airbag deployment. Covering method using tires: Place at least 3 tires without disc wheel on top of the disc wheel with tire to which the steering wheel pad is tied. Tire size: Must exceed the following dimensions− Width: 185 mm (7.87 in.) Inner diameter: 360 mm (14.17 in.) CAUTION: Do not use tires with disc wheels. NOTICE: The tires may be marked by the airbag deployment, so use the redundant tires. (g) Deploy the airbag. (1) Connect the SST red clip to the battery positive (+) terminal and the black clip to the battery negative (−) terminal. (2) Check that no one is within 10 m (33 ft) area around the disc wheel which the steering wheel pad is tied to. S Inner Diam Width Tires (3 or More) R04211 (3) Press the SST activation switch and deploy the airbag. HINT: The airbag deploys simultaneously as the LED of the SST activation switch lights up. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark RS−18 SUPPLEMENTAL RESTRAINT SYSTEM AB0166 − STEERING WHEEL PAD AND SPIRAL CABLE (h) Dispose of the steering wheel pad (with airbag). CAUTION: S The steering wheel pad is very hot when the airbag is deployed, so leave it alone for at least 30 minutes after deployment. S Use gloves and safety glasses when handling a steering wheel pad with deployed airbag. S Always wash your hands with water after completing the operation. S Do not apply water, etc. to a steering wheel pad with deployed airbag. (1) Remove the steering wheel pad from the disc wheel. (2) Place the steering wheel pad in a vinyl bag, tie the end tightly and dispose of it in the same way as other general parts disposal. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark RS−19 SUPPLEMENTAL RESTRAINT SYSTEM − STEERING WHEEL PAD AND SPIRAL CABLE RS0RT−01 REPLACEMENT REPLACEMENT REQUIREMENTS In the following cases, replace the steering wheel pad, steering wheel or spiral cable. Case Replacing part If the airbag has been deployed. Steering wheel pad If the steering wheel pad has been found to be faulty in troubleshooting. Steering wheel pad If the spiral cable has been found to be faulty in troubleshooting. Spiral cable If the steering wheel pad has been found to be faulty during checking items. (See page RS−9) Steering wheel pad If the steering wheel has been found to be faulty during checking items. (See page RS−9) Steering wheel If the spiral cable has been found to be faulty during checking items. (See page RS−9) Spiral cable If the steering wheel pad has been dropped. Steering wheel pad CAUTION: For removal and installation of the steering wheel pad, see pages SR−11 and SR−19, and be sure to follow the correct procedure. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark RS−20 SUPPLEMENTAL RESTRAINT SYSTEM − STEERING WHEEL PAD AND SPIRAL CABLE RS0P6−01 INSTALLATION INSTALL STEERING WHEEL AND SPIRAL CABLE (See page RS−7) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark RS−21 SUPPLEMENTAL RESTRAINT SYSTEM − FRONT PASSENGER AIRBAG ASSEMBLY FRONT PASSENGER AIRBAG ASSEMBLY RS0P7−01 COMPONENTS 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 1120 Brought to you by BirfMark RS−22 SUPPLEMENTAL RESTRAINT SYSTEM − FRONT PASSENGER AIRBAG ASSEMBLY REMOVAL RS0P8−01 NOTICE: If the wiring connector of the SRS is disconnected with the ignition switch at ON or ACC, DTCs will be recorded. 1. DISCONNECT AIRBAG CONNECTOR (a) Remove the glove compartment door (See page BO−76). (b) Remove the airbag connector from the airbag bracket. NOTICE: When handling the airbag connector, take care not to damage the airbag wire harness. (c) Disconnect the airbag connector. 2. 3. (a) REMOVE INSTRUMENT PANEL (See pages BO−76) REMOVE FRONT PASSENGER AIRBAG ASSEMBLY Remove the 4 bolts and 2 nuts, and remove front passenger airbag assembly. (b) Pry up the 6 clips shown in the illustration and remove the airbag door. CAUTION: Do not store the front passenger airbag assembly with the airbag deployment direction facing down.Never disassemble the front passenger airbag assembly. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark RS−23 SUPPLEMENTAL RESTRAINT SYSTEM − FRONT PASSENGER AIRBAG ASSEMBLY INSPECTION RS0P9−01 1. (a) (b) VEHICLES NOT INVOLVED IN COLLISION Do a diagnostic system check (See page DI−240). Do a visual check which includes the following items with the front passenger airbag assembly installed in the vehicle. Check cuts, minute cracks or marked discoloration on the front passenger airbag assembly and instrument panel. 2. VEHICLE INVOLVED IN COLLISION AND AIRBAG IS NOT DEPLOYED Do a diagnostic system check (See page DI−240). Do a visual check which includes the following items with the front passenger airbag assembly removed from the vehicle. S Check cuts, minute cracks or marked discoloration on the front passenger airbag assembly. S Check cuts and cracks in wire harnesses, and for chipping in connectors. S Check the deformation or cracks on the instrument panel and instrument panel reinforcement. (a) (b) HINT: If the instrument panel or instrument panel reinforcement is deformed or cracked, never repair it. Always replace it with a new one. CAUTION: For removal and installation of the front passenger airbag assembly, see page RS−22 and RS−31 and be sure to follow the correct procedure. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark RS−24 SUPPLEMENTAL RESTRAINT SYSTEM 3. (a) (b) − FRONT PASSENGER AIRBAG ASSEMBLY VEHICLE INVOLVED IN COLLISION AND AIRBAG IS DEPLOYED Do a diagnostic system check (See page DI−240). Do a visual check which includes the following items with the front passenger airbag assembly removed from the vehicle. S Check the deformation or cracks on the instrument panel and instrument panel reinforcement. S Check the damage on the connector and wire harness. HINT: If the instrument panel or instrument panel reinforcement is deformed or cracked, never repair it. Always replace it with a new one. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark RS−25 SUPPLEMENTAL RESTRAINT SYSTEM − FRONT PASSENGER AIRBAG ASSEMBLY DISPOSAL RS0PB−01 HINT: When scrapping vehicle equipped with an SRS or disposing of a front passenger airbag assembly, always first deploy the airbag in accordance with the procedure described below. If any abnormality occurs with the airbag deployment, contact the SERVICE DEPT. of TOYOTA MOTOR SALES, U.S.A., INC. When disposing of a front passenger airbag assembly with an airbag deployed in a collision, follow the same procedure given in step 1−(e) in ”DISPOSAL”. SST AB0152 CAUTION: S Never dispose of a front passenger airbag assembly which has an undeployed airbag. S The airbag produces a sizeable exploding sound when it deploys, so perform the operation out of doors and where it will not create a nuisance to nearby residents. S When deploying the airbag, always use the specified SST (SRS Airbag Deployment Tool). Perform the operation in a place away from electrical noise. SST 09082−00700 S When deploying an airbag, perform the operation at least 10 m (33 ft) away from the front passenger airbag assembly. S The front passenger airbag assembly is very hot when the airbag is deployed, so leave it alone for at least 30 minutes after deployment. S Use gloves and safety glasses when handling a front passenger airbag assembly with deployed airbag. S Always wash your hands with water after completing the operation. S Do not apply water, etc. to a front passenger airbag assembly with deployed airbag. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark RS−26 SUPPLEMENTAL RESTRAINT SYSTEM 1. − FRONT PASSENGER AIRBAG ASSEMBLY AIRBAG DEPLOYMENT WHEN SCRAPPING VEHICLE HINT: Have a battery ready as the power source to deploy the airbag. (a) Check functioning of the SST. (See page RS−11) Battery SST AB0158 (b) Disconnect the airbag connector. (1) Remove the glove compartment door. (2) Remove the No.1 under cover. NOTICE: When handling the airbag connector, take care not to damage the airbag wire harness. (3) Pull up the connector. (4) Disconnect the airbag connector. (c) Install the SST. (1) Connect the SST connector to the front passenger airbag assembly connector. SST 09082−00700 NOTICE: To avoid damaging the SST connector and wire harness, do not lock the secondary lock of the twin lock. SST (2) Move the SST to at least 10 m (33 ft) away from the front of the vehicle. Close all the doors and windows of the vehicle. (3) NOTICE: Take care not to damage the SST wire harness. (4) Connect the SST red clip to the battery positive (+) terminal and the black clip to the negative (+) terminal. 10 m (33 ft) or more ← → R13455 (d) Deploy the airbag. (1) Confirm that no one is inside the vehicle or within 10 m (33 ft) area around the vehicle. (2) Press the SST activation switch and deploy the airbag. HINT: The airbag deploys simultaneously as the LED of the SST activation switch lights up. H03286 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark RS−27 SUPPLEMENTAL RESTRAINT SYSTEM − FRONT PASSENGER AIRBAG ASSEMBLY (e) Dispose of the front passenger airbag assembly. CAUTION: S The front passenger airbag assembly is very hot when the airbag is deployed, so leave it alone for at least 30 minutes after deployment. S Use gloves and safety glasses when handling a front passenger airbag assembly with deployed airbag. S Always wash your hands with water after completing the operation. S Do not apply water, etc. to a front passenger airbag assembly with deployed airbag. (1) When scrapping a vehicle, deploy the airbag and scrap the vehicle with the front passenger airbag assembly still installed. (2) When moving a vehicle for scrapping which has a front passenger airbag assembly with deployed airbag, use gloves and safety glasses. 2. DEPLOYMENT WHEN DISPOSING OF FRONT PASSENGER AIRBAG ASSEMBLY ONLY NOTICE: S When disposing of the front passenger airbag assembly only, never use the customer’s vehicle to deploy the airbag. S Be sure to follow the procedure given below when deploying the airbag. HINT: Have a battery ready as the power source to deploy the airbag. (a) Wire Harness Diameter Remove the front passenger airbag assembly. (See page RS−22) CAUTION: S When removing the front passenger airbag assembly, work must be started 90 seconds after the ignition switch is turned to the ”LOCK” position and the negative (−) terminal cable is disconnected from the battery. S Store the front passenger airbag assembly with the airbag deployment side facing upward. (b) Using a service−purpose wire harness for the vehicle, tie down the front passenger airbag assembly to the tire. Wire harness: Stripped wire harness section 1.25 mm2 or more (0.0019 in.2 or more) HINT: To calculate the square of the stripped wire harness section: Square = 3.14 X (Diameter)2 divided by 4 Stripped Wire Harness Section AB0163 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark RS−28 SUPPLEMENTAL RESTRAINT SYSTEM − FRONT PASSENGER AIRBAG ASSEMBLY CAUTION: If the front passenger airbag assembly is tied down with too thin wire harness, it may snap. This is highly dangerous. Always use a wire harness which is at least 1.25 mm2 (0.0019 in.2) (1) Wind the wire harness around the tire, passing the wire harness through the installation holes indicated by arrows in the illustration. (2) Width Inner Diam. R11891 Position the front passenger airbag assembly inside the tire with the airbag deployment side facing inside. Tire size: Must exceed the following dimensions− Width: 185 mm (7.28 in.) Inner diameter: 360 mm (14.17 in.) CAUTION: S Make sure that the wire harness is tight. It is very dangerous if looseness in the wire harness results in the front passenger airbag assembly coming free due to the shock from the airbag deploying. S Always tie down the front passenger airbag assembly with the airbag deployment side facing inside. NOTICE: The tire will be marked by the airbag deployment, so use a redundant tire. (c) Check functioning of the SST. SST 09082−00700 (d) Place tires. (1) Place at least 2 tires under the tire to which the front passenger airbag assembly is tied. (2) Place at least 2 tires over the tire to which the front passenger airbag assembly is tied. The top tire should have the wheel installed. Battery SST AB0158 Tires (5 or more) R09689 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark RS−29 SUPPLEMENTAL RESTRAINT SYSTEM − FRONT PASSENGER AIRBAG ASSEMBLY (3) Tie the tires together with 2 wire harnesses. CAUTION: Make sure that the wire harnesses are tight. It is very dangerous if loose wire harnesses result in the tires coming free due to the shock from the airbag deploying. HINT: Place the SST connector and wire harness inside tires. Provide at least 1 m (3 ft) of slack for the wire harness. R05403 (e) Battery SST Front Passenger Airbag Assembly 10 mm (33 ft) or more R09690 R09687 Install the SST. Connect the SST connector to the front passenger airbag assembly connector. SST 09082−00700 NOTICE: To avoid damaging the SST connector and wire harness, do not lock the secondary lock of the twin lock. (f) Deploy the airbag (1) Connect the SST red clip to the battery positive (+) terminal and the black clip to the battery negative (−) terminal. (2) Confirm that no one is within 10 m (33 ft) area around the tire which the front passenger airbag assembly is tied to. (3) Press the SST activation switch and deploy the airbag. HINT: The airbag deploys simultaneously as the LED of the SST activation switch lights up. (g) Dispose of the front passenger airbag assembly. CAUTION: S The front passenger airbag assembly is very hot when the airbag is deployed, so leave it alone for at least 30 minutes after deployment. S Use gloves and safety glasses when handling a front passenger airbag assembly with deployed airbag. S Always wash your hands with water after completing the operation. S Do not apply water, etc. to a front passenger airbag assembly with deployed airbag. (1) Remove the front passenger airbag assembly from the tire. (2) Place the front passenger airbag assembly in a vinyl bag, tie the end tightly and dispose of it in the same way as other general parts disposal. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark RS−30 SUPPLEMENTAL RESTRAINT SYSTEM − FRONT PASSENGER AIRBAG ASSEMBLY RS0PA−01 REPLACEMENT REPLACEMENT REQUIREMENTS In the following cases, replace the front passenger airbag assembly, instrument panel or instrument panel reinforcement. Case Replacing part If the airbag has been deployed. Front passenger airbag assembly If the front passenger airbag assembly has been found to be faulty in troubleshooting. Front passenger airbag assembly If the front passenger airbag assembly has been found to be faulty during checking items. (See page RS−23) Front passenger airbag assembly If the instrument panel has been found to be faulty during checking items. (See page RS−23) Instrument panel If the instrument panel reinforcement has been found to be faulty during checking items. (See page RS−23) Instrument panel reinforcement If the front passenger airbag assembly has been dropped. Front passenger airbag assembly CAUTION: For replacement of the front passenger airbag assembly, see page RS−22 and RS−31. Be sure to follow the correct procedure. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark RS−31 SUPPLEMENTAL RESTRAINT SYSTEM − FRONT PASSENGER AIRBAG ASSEMBLY INSTALLATION RS0PC−03 NOTICE: Never use airbag parts from another vehicle. When replacing parts, replace with new parts. 1. INSTALL FRONT PASSENGER AIRBAG ASSEMBLY Install the airbag door and front passenger airbag assembly to the instrument panel. CAUTION: S Make sure that no foreign objects are trapped between the airbag and the module. S Do not damage the strap when installing the module. If the airbag door is cracked or its surface is peeling, always replace it with a new airbag door. NOTICE: If the front passenger airbag assembly has been dropped, or there are cracks, dents or other defects in the case or connector, replace the front passenger airbag assembly with a new one. 2. INSTALL INSTRUMENT PANEL (See page BO−80) Install the 2 bolts to instrument panel reinforcement. Torque: 20 N·m (210 kgf·cm, 15 ft·lbf) NOTICE: Make sure the front passenger airbag assembly is installed to the specified torque.When installing the instrument panel, take care that the airbag wire harness does not interfere with other parts and is not pinched between other parts. 3. (a) (b) (c) CONNECT AIRBAG CONNECTOR Connect the airbag connector. Install the airbag connector to the airbag bracket. Install the glove compartment door. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark RS−32 SUPPLEMENTAL RESTRAINT SYSTEM − AIRBAG SENSOR ASSEMBLY AIRBAG SENSOR ASSEMBLY RS0PD−01 COMPONENTS 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 1131 Brought to you by BirfMark RS−33 SUPPLEMENTAL RESTRAINT SYSTEM − AIRBAG SENSOR ASSEMBLY REMOVAL RS0PE−01 NOTICE: Do not open the cover or the case of the ECU and various computers unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) 1. REMOVE THESE PARTS: (a) Transfer shirt knob (b) Front console box 2. REMOVE AIRBAG SENSOR ASSEMBLY (a) Disconnect the connector. NOTICE: Remove the connector with the sensor assembly installed. (b) Using a torx wrench remove the 4 screws and the airbag sensor assembly. Torx wrench: T40 (Part No. 09042−00020 or locally manufactured tool) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark RS−34 SUPPLEMENTAL RESTRAINT SYSTEM − AIRBAG SENSOR ASSEMBLY RS0PH−01 INSPECTION 1. VEHICLE NOT INVOLVED IN COLLISION Do a diagnostic system check. (See page DI−240) 2. VEHICLE INVOLVED IN COLLISION AND AIRBAG IS NOT DEPLOYED Do a diagnostic system check. (See page DI−240) 3. VEHICLE INVOLVED IN COLLISION AND AIRBAG IS DEPLOYED Replace the airbag sensor assembly. (See page RS−32) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark RS−35 SUPPLEMENTAL RESTRAINT SYSTEM − AIRBAG SENSOR ASSEMBLY RS0PG−01 REPLACEMENT REPLACEMENT REQUIREMENTS In the following cases, replace the airbag sensor assembly. S If the SRS has been deployed in a collision. S If the airbag sensor assembly has been found to be faulty in troubleshooting. S If the airbag sensor assembly has been dropped. CAUTION: For removal and installation of the airbag sensor assembly, see page RS−33 and RS−36. Be sure to follow the correct procedure. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark RS−36 SUPPLEMENTAL RESTRAINT SYSTEM − AIRBAG SENSOR ASSEMBLY RS0PF−01 INSTALLATION NOTICE: S Never use SRS parts from another vehicle. When replacing parts, replace with new parts. S Never reuse the airbag sensor assembly involved in a collision when the airbag has deployed. S Never repair a sensor in order to reuse it. 1. INSTALL AIRBAG SENSOR ASSEMBLY (a) Using a torx wrench, install the airbag sensor assembly with the 4 screws. Torx wrench: T40 (Part No. 09042−00020 or locally manufactured tool) Torque: 21 N·m (210 kgf·cm, 15 ft·lbf) (b) Connect the connector. NOTICE: S Installation of the connector is done with the sensor assembly installed. S Make sure the sensor assembly is installed to the specified torque. S If the sensor assembly has been dropped, or there are cracks, dents or other defects in the case, bracket or connector, replace the sensor assembly with a new one. S When installing the sensor assembly, take care that the SRS wiring does not interfere with other parts and is not pinched between other parts. S After installation, shake the sensor assembly to check that there is no looseness. 2. INSTALL THE REMOVED PARTS 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark RS−37 SUPPLEMENTAL RESTRAINT SYSTEM − WIRE HARNESS AND CONNECTOR WIRE HARNESS AND CONNECTOR RS0PK−01 LOCATION Front Passenger Airbag Assembly Steering Wheel Pad Airbag Sensor Assembly R13515 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 1136 Brought to you by BirfMark RS−38 SUPPLEMENTAL RESTRAINT SYSTEM − WIRE HARNESS AND CONNECTOR RS0PJ−01 INSPECTION HINT: The SRS wire harness is integrated with the cowl wire harness assembly and floor wire harness assembly. The wires for the SRS wire harness are encased in a black corrugated tube and all the connectors in the system are a standard yellow color. 1. VEHICLES NOT INVOLVED IN COLLISION Do a diagnostic system check (See page DI−240). 2. VEHICLES INVOLVED IN COLLISION (a) Do a diagnostic system check (See page DI−240). (b) Check for breaks in all wires of the SRS wire harness, and for exposed conductors. (c) Check to see if the SRS wire harness connectors are cracked or chipped. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark RS−39 SUPPLEMENTAL RESTRAINT SYSTEM − WIRE HARNESS AND CONNECTOR RS0PI−01 REPLACEMENT In the following cases, replace the wire harness or connector. S If any part of the SRS wire harness or any connector has been found to be faulty in troubleshooting. S If any part of the SRS wire harness or any connector has been found to be faulty during the check in items 2−(b) or (c). NOTICE: If the wire harness used in the SRS is damaged, replace the whole wire harness assembly. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SA−1 SUSPENSION AND AXLE − TROUBLESHOOTING TROUBLESHOOTING SA1U7−01 PROBLEM SYMPTOMS TABLE Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely cause of the problem. Check each part in order. If necessary, replace these parts. (w/ Differential locking system): S Check that center differential lock mode is set. S When switching differential Free↔Lock, the indicator lamp will blink if the gears of the differential lock sleeve are not meshed. If this occurs, when the tires are rotated to apply differential power to the differential, the differential locks and the indicator lamp light up. Symptom Suspect Area See page Wander/ pulls 1. 2. 3. 4. 5. Tires: worn or improperly inflated Wheel alignmemt: incorrect Steering linkage: loosen or worn Hub bearings: loosen or worn Steering gear: out of adjustment or broken SA−3 SA−4 SR−47 SA−8 SR−41 Bottoming 1. Vehicle: overloaded 2. Spring weak 3. Shock absorber: worn out − SA−49 SA−49 Sways/ pitches 1. Tires: worn or improperly inflated 2. Stabilizer bar: bent or broken 3. Shock absorber: worn out SA−3 SA−60 SA−49 Front wheel shimmy 1. 2. 3. 4. 5. 6. 7. Tires: worn or improperly inflated Wheels: out of balance Shock absorber: worn out Wheel alignmemt: incorrect Hub bearings: loosen or worn Steering linkage: loosen or worn Steering gear: out of adjustment or broken SA−3 SA−3 SA−49 SA−3 SA−7 SR−45 SR−38 Abnormal tire wear 1. 2. 3. 4. Tires: worn or improperly inflated Wheel alignmemt: incorrect Suspension parts: worn out Shock absorber: worn out SA−3 SA−3 − SA−49 Noise in front differential 1. 2. 3. 4. 5. 6. Oil level: low or wrong grade Excessive backlash between pinion and ring gear Ring, pinion ro side gears: worn or chipped Pinion shaft bearing: worn Side bearing: worn Differential bearing: loosen or worn SA−21 SA−29 SA−29 SA−29 SA−29 SA−29 Oil leak from front differential 1. 2. 3. 4. 5. Oil level: too high or wrong grade Drive pinion oil seal: worn or damaged Side gear oil seal: worn or damaged Companion flange: loosen or damaged Side gear shaft: damaged SA−21 SA−29 SA−29 SA−29 SA−29 Noise in rear axle 1. 2. 3. 4. 5. 6. Oil level: low or wrong grade Excessive backlash between pinion and ring gear Ring, pinion ro side gears: worn or chipped Pinion shaft bearing: worn Axle shaft bearing: worn Differential bearing: loosen or worn SA−73 SA−87 SA−87 SA−87 SA−87 SA−87 Oil leak from rear axle 1. Oil seal: worn or damaged 2. Rear axle housing: cracked SA−73 − 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 858 Brought to you by BirfMark SA−2 SUSPENSION AND AXLE − TROUBLESHOOTING Oil leak from rear differential 1. Oil level: too high or wrong grade 2. Oil seal: worn or damaged 3. Companion flange: loosen or damaged SA−73 SA−73 SA−87 Indicator lights do not light up 1. 2. 3. 4. Fusible link: blown GAUGE fuse: blown Bulb: burned out Wiring or ground: faulty BE−9 BE−9 BE−32 − Indicator lights do not light up (Diff. lock control switch RR or FR RR position) 1. 2. 3. 4. DIFF fuse: blown Diff. lock control switch: faulty Diff. lock ECU: faulty Wiring or ground: faulty BE−9 SA−101 SA−101 − Differential lock does not operate 1. 2. 3. 4. 5. Diff. lock position switch: faulty Diff. lock actuator: faulty Diff. lock ECU: faulty Differential carrier (Diff. lock): faulty Wiring or ground: faulty SA−101 SA−101 SA−101 SA−101 − After differential lock, lock not release When vehicle speed is higher than approx. 8 km/h (5mph) 1. Speed sensor: faulty 2. Diff. lock ECU: faulty 3. Wiring or ground: faulty BE−32 SA−101 − 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 859 Brought to you by BirfMark SA−3 SUSPENSION AND AXLE − TIRE AND WHEEL TIRE AND WHEEL SA1U8−02 INSPECTION 1. (a) INSPECT TIRE Check the tires for wear and for the proper inflation pressure. Cold tire inflation pressure: See page SS−30 (b) Check the tire runout. Tire runout: 3.0 mm (0.118 in.) or less R03031 2. ROTATE TIRES HINT: See the illustration for where to rotate each tire. R13503 3. (a) (b) R07928 INSPECT WHEEL BALANCE Check and adjust the Off−the−car balance. If necessary, check and adjust the On−the−car balance. Unbalance after adjustment: 13.0 g (0.029 lb) or less 4. CHECK WHEEL BEARING LOOSENESS Check the no backlash in the bearing shaft direction. 5. CHECK FRONT SUSPENSION FOR LOOSENESS 6. CHECK STEERING LINKAGE FOR LOOSENESS 7. CHECK BALL JOINT FOR LOOSENESS 8. CHECK SHOCK ABSORBER WORKS PROPERLY S Check for oil leaks S Check mounting bushings for wear S Bounce front and rear of the vehicle 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 860 Brought to you by BirfMark SA−4 SUSPENSION AND AXLE − FRONT WHEEL ALIGNMENT FRONT WHEEL ALIGNMENT INSPECTION SA1U9−02 1. MEASURE VEHICLE HEIGHT Clearance: A (Follow spring clearance): 36 mm (1.42 in.) B (Bumper stopper clearance): 104 mm (4.09 in.) If the clearance of the vehicle is not standard, try to level the vehicle by rocking it down. If still not correct, check for bad springs or suspension parts. 2. INSTALL CAMBER−CASTER−KINGPIN GAUGE OR ONTO WHEEL ALIGNMENT TESTER Follow the specific instructions of the equipment manufacturer. 3. INSPECT CAMBER, CASTER AND STEERING AXIS INCLINATION Camber Left−right error 1°00’ ± 45 45’ or less Left−right error 3°00’ ± 1° 45’ or less Caster Z03382 Steering axis inclination 13°00’ ± 45’ Camber, caster and steering axis inclination are not adjustable. If measurements are not within the specification, inspect the suspension parts for damaged and/or worn out parts and replace them as necessary. A B D Front 4. INSPECT TOE−IN Toe−in (total) A+B: 0.2° ± 0.2° C−D: 2 ± 2 mm (0.08 ± 0.08 in.) If toe−in is not within the specification, adjust by the tie rod end. C SA3213 5. ADJUST TOE−IN (a) Loosen the clamp bolts and nuts. (b) Adjust toe−in to the correct value by turning the tie rod. HINT: Make sure that the lengths of the left and right tie rod ends are the same. (c) Torque the clamp bolts and nuts. Torque: 37 N·m (375 kgf·cm, 27 ft·lbf) B A A=B R05628 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 861 Brought to you by BirfMark SA−5 SUSPENSION AND AXLE +10° − FRONT WHEEL ALIGNMENT HINT: The clamps opening must be positioned at the rear of the tie rod end face within 60°±10° from the vehicle axis. +60° −10° Front Side R05626 6. (a) INSPECT WHEEL ANGLE Remove the caps of the knuckle stopper bolts and check the steering angles. (b) Turn the steering wheel fully, and measure the turning angle. FA0507 A B B A Front A: Inside B: Outside FA0018 Inside wheel 32°00’ − 35°00’ Outside wheel 31°00’ (Reference) HINT: When the steering wheel is fully turned, make sure that the wheel is not 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: 44 N·m (450 kgf·cm, 33 ft·lbf) If the wheel angle still cannot be adjusted within limits, inspect and replace damaged or worn steering parts. 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 862 Brought to you by BirfMark SA−6 SUSPENSION AND AXLE − FRONT AXLE HUB FRONT AXLE HUB SA1UA−01 COMPONENTS 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 863 Brought to you by BirfMark SA−7 SUSPENSION AND AXLE − FRONT AXLE HUB REMOVAL 1. 2. REMOVE FRONT WHEEL REMOVE BRAKE CALIPER (See page BR−25) 3. (a) REMOVE FLANGE Using a screwdriver and hammer, remove the grease cap from the flange. Using a snap ring expander, remove the snap ring. Loosen the 6 mounting nuts. Using a brass bar and hammer, tap on the 6 bolts heads and remove the 6 cone washers, plate washers and nuts. Remove the flange. Remove the gasket. (b) (c) (d) (e) (f) 4. (a) (b) (c) (d) (e) 5. (a) SST SA1UB−01 (b) REMOVE AXLE HUB WITH DISC Using a screwdriver, release the lock washer. Using SST, remove the lock nut. SST 09607−60020 Remove the lock washer. Using SST, remove the adjusting nut and thrust washer. SST 09607−60020 Remove the hub and disc together with the outer bearing. REMOVE OIL SEAL AND INNER BEARING Using SST, remove the oil seal. SST 09308−00010 Remove the inner bearing from the hub. SA2635 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SA−7 SUSPENSION AND AXLE − FRONT AXLE HUB REMOVAL 1. 2. REMOVE FRONT WHEEL REMOVE BRAKE CALIPER (See page BR−25) 3. (a) REMOVE FLANGE Using a screwdriver and hammer, remove the grease cap from the flange. Using a snap ring expander, remove the snap ring. Loosen the 6 mounting nuts. Using a brass bar and hammer, tap on the 6 bolts heads and remove the 6 cone washers, plate washers and nuts. Remove the flange. Remove the gasket. (b) (c) (d) (e) (f) 4. (a) (b) (c) (d) (e) 5. (a) SST SA1UB−01 (b) REMOVE AXLE HUB WITH DISC Using a screwdriver, release the lock washer. Using SST, remove the lock nut. SST 09607−60020 Remove the lock washer. Using SST, remove the adjusting nut and thrust washer. SST 09607−60020 Remove the hub and disc together with the outer bearing. REMOVE OIL SEAL AND INNER BEARING Using SST, remove the oil seal. SST 09308−00010 Remove the inner bearing from the hub. SA2635 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SA−9 SUSPENSION AND AXLE − FRONT AXLE HUB INSTALLATION 1. (a) (b) Grease (c) 2. SA1UD−01 PACK BEARINGS WITH MP GREASE Place MP grease on the palm of your hand. Pack grease into the bearing until the grease oozes out from the other side. Do the same around the bearing circumference. COAT INSIDE OF HUB WITH MP GREASE SA2636 3. (a) (b) SST R04134 (c) 4. (a) (b) (c) 5. (a) (b) (c) (d) INSTALL INNER BEARING AND OIL SEAL Place the inner bearing into the hub. Using SST, install a new oil seal into the hub. SST 09950−60020 (09951−00910), 09950−70010 (09951−07150) Coat the oil seal lip with MP grease. INSTALL AXLE HUB WITH DISC TO SPINDLE Place the axle hub with disc to the spindle. Install the outer bearing. Install the thrust washer. ADJUST PRELOAD Using SST, torque the adjusting nut. SST 09607−60020 Torque: 59 N·m (600 kgf·cm, 43 ft·lbf) Turn the hub right and left 2 or 3 times. Using SST, torque the adjusting nut. SST 09607−60020 Torque: 59 N·m (600 kgf·cm, 43 ft·lbf) Loosen the nut until it can be turned by hand. (e) Using SST, torque the adjusting nut again. SST 09607−60020 Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf) NOTICE: Check that the bearing has no play. (f) Using a spring tension gauge, measure the preload. Preload (at starting): 28 − 56 N (2.9 − 5.7 kgf, 6.4 − 12.6 lbf) 6. INSTALL LOCK WASHER AND LOCK NUT (a) Install a new lock washer and lock nut. (b) Using SST, torque the lock nut. SST 09607−60020 Torque: 64 N·m (650 kgf·cm, 47 ft·lbf) (c) Check that axle hub turns smoothly and that the bearing has no play. (d) Using a spring tension gauge, check the preload. Preload (at starting): 28−56 N (2.9−5.7 kgf, 6.4−12.6 lbf) If it is not within the specification, adjust it with the adjusting nut after removing the lock washer and lock nut. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SA−10 SUSPENSION AND AXLE (e) 7. (a) (b) (c) (d) (e) (f) (g) (h) (i) (j) 8. 9. R08416 10. − FRONT AXLE HUB Secure the lock nut by bending one of the lock washer teeth inward and the other lock washer teeth outward. INSTALL FLANGE Place a new gasket in position on the axle hub. Apply MP grease to the inner flange splines. Install the flange to the axle hub. Install the 6 cone washers, plate washers and nuts. Torque the 6 nuts. Torque: 35 N·m (360 kgf·cm, 26 ft·lbf) Install the bolt in the axle shaft and pull it out. Using a snap ring expander, install a new snap ring. Remove the bolt. Coat inside of the cap with MP grease. Install the cap to the flange. INSTALL BRAKE CALIPER (See page BR−29) INSTALL FRONT WHEEL Torque: Steel wheel: 147 N·m (1,500 kgf·cm, 109 ft·lbf) Alumimum wheel: 103 N·m (1,050 kgf·cm, 76 ft·lbf) BLEED BRAKE LINE 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SA−11 SUSPENSION AND AXLE − FRONT WHEEL HUB BOLT FRONT WHEEL HUB BOLT REPLACEMENT SA1UE−01 1. REMOVE FRONT AXLE HUB (See page SA−7) 2. (a) (b) (c) (d) REPLACE HUB BOLTS Place matchmarks on the axle hub and disc. Remove the 6 bolts and disc from the axle hub. Install the nut to the hub bolt. Using an extension bar and a press, remove the hub bolt. (e) (f) (g) Using an extension bar and press, install a new hub bolt. Align the matchmarks on the axle hub and disc. Install and torque the 6 bolts. Torque: 64 N·m (650 kgf·cm, 47 ft·lbf) INSTALL FRONT AXLE HUB (See page SA−9) 3. 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 868 Brought to you by BirfMark SA−12 SUSPENSION AND AXLE − STEERING KNUCKLE AND AXLE SHAFT STEERING KNUCKLE AND AXLE SHAFT SA1UF−01 COMPONENTS 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 869 Brought to you by BirfMark SA−13 SUSPENSION AND AXLE − STEERING KNUCKLE AND AXLE SHAFT REMOVAL SA1UG−01 1. REMOVE FRONT AXLE HUB (See page SA−7) 2. REMOVE ABS SPEED SENSOR Remove the 2 bolts and disconnect the speed sensor from the steering knuckle. W00495 3. REMOVE DUST SEAL AND DUST COVER Remove the 8 bolts, dust seal, dust cover and gasket. 4. REMOVE KNUCKLE SPINDLE (a) Using a brass bar and hammer, tap the knuckle spindle of the steering knuckle. (b) Remove the knuckle spindle and gasket. 5. REMOVE AXLE SHAFT Position one flat part of the outer shaft upward and remove the axle shaft. 6. (a) (b) DISCONNECT TIE ROD FROM KNUCKLE ARM Remove the cotter pin and nut. Using SST, disconnect the tie rod from the knuckle arm. SST 09611−22012 7. (a) (b) REMOVE OIL SEAL SET Remove the 6 bolts from the end retainer. Remove these parts from the steering knuckle: S Oil seal end retainer S Felt dust seal S Rubber seal S Steel ring 8. (a) REMOVE KNUCKLE ARM AND BEARING CAP Remove the 2 bolts and plate washers from the bearing cap. Remove the 4 nuts from the knuckle arm. Using a brass bar and hammer, tap on the 4 bolts heads and remove the 4 cone washers. SST SA2644 R08383 (b) (c) R13137 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SA−14 SUSPENSION AND AXLE (d) − STEERING KNUCKLE AND AXLE SHAFT Using SST, remove the bearing cap and shim from the steering knuckle. SST 09606−60020 HINT: S S Use the SST without a collar. In some cases, to satisfy the standard value of preload, more than one shims are used. (e) Using SST, remove the knuckle arm and shim from the steering knuckle. SST 09606−60020 HINT: S S Use the SST without a collar. In some cases, to satisfy the standard value of preload, more than one shims are used. REMOVE STEERING KNUCKLE AND BEARING 9. HINT: Mark the removed adjusting shim and bearings so as to enable reassembling them to their proper positions. 10. REMOVE OIL SEAL TO AXLE HOUSING Using SST, remove the oil seal. SST 09308−00010 SST Q07149 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SA−15 SUSPENSION AND AXLE − STEERING KNUCKLE AND AXLE SHAFT REPLACEMENT SA1UH−01 1. INSPECT KNUCKLE SPINDLE Clean the knuckle spindle and inspect the bushing for wear or damage. 2. (a) SST SST R08435 REPLACE BUSHING Using SST, remove the bushing. SST 09612−65014 (09612−01010, 09612−01050) (b) Using SST and a press, install a new bushing into the spindle. SST 09618−60010 3. INSPECT BEARING Clean the bearing and 2 outer races and inspect them for wear or damage. 4. (a) (b) IF NECESSARY, REPLACE BEARING OUTER RACE Using a brass bar and hammer, remove the bearing outer race. Using SST and a hammer, carefully install a new bearing outer race. SST 09605−60010 Z06889 5. (a) (b) (c) INSPECT BIRFIELD JOINT INNER PARTS Hold the inner shaft in a vise. Place a brass bar against the joint inner race and remove the outer shaft. Tilt the inner race and cage and take out the bearing balls one by one. FA0203 (d) (e) (f) Fit the 2 large openings in the cage against the protruding parts of the outer shaft and remove the cage and inner race. Remove the inner race from the cage though the large opening. Clean and inspect the joint parts for wear or damage. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SA−16 SUSPENSION AND AXLE (g) (h) (i) (j) (k) (l) (m) (n) (o) (p) − STEERING KNUCKLE AND AXLE SHAFT Coat the joint inner parts and outer shaft inside with molybdenum disulpfide lithium base grease, NLGI No.2. Install the inner race in the cage through the large opening. Position the protruding end of the inner race toward the wide side of the cage. Assemble the cage and inner race to the outer shaft by fitting the 2 large openings in the cage against the protruding parts of the outer shaft. Make sure to position the wide side of the cage and the inner race protruding end outward. Fit in the inner race and cage and install the 6 bearing balls in the outer shaft (See step (c)). Pack molybdenum disulpfide lithium base grease, NLGI No.2 in the outer shaft. Install a new snap ring on the inner shaft. Hold the outer shaft in a vise and while compressing the snap ring, install the inner shaft to the outer shaft. Make sure that the inner shaft cannot be pulled out. FA0107 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SA−17 SUSPENSION AND AXLE − STEERING KNUCKLE AND AXLE SHAFT INSTALLATION SST SA2650 Lithium Base Wheel Bearing Grease, NIGI No.2 Z15221 1. INSTALL OIL SEAL TO AXLE HOUSING Using SST and a hammer, install a new oil seal into the axle housing. SST 09618−60010 2. INSTALL OIL SEAL SET Install these parts to the steering knuckle: S Oil seal and retainer S Felt dust seal S Rubber seal and steel ring 3. PACK BEARINGS WITH LITHIUM BASE WHEEL BEARING GREASE, NLGI NO.2 (a) Place lithium base wheel bearing grease, NLGI No.2 on your hand. (b) Pack grease into the bearing until the grease oozes out from the outer side. (c) Do the same around the bearing circumference. 4. INSTALL STEERING KNUCKLE AND BEARINGS (a) Place the bearings in positions on the knuckle and axle housing. (b) Install the knuckle on the axle housing. 5. (a) SST R08387 R08388 INSTALL KNUCKLE ARM AND BEARING CAP Using SST, support the upper bearing inner race. SST 09606−60020 HINT: Use the SST with a collar. (b) Install the bearing cap over the shim that were originally used. (c) Using a hammer, install the bearing cap into the bearing inner race. (d) SST SA1UI−01 Using SST, support the lower bearing inner race. SST 09606−60020 HINT: Use the SST with a collar. (e) Using a hammer, tap the knuckle arm and shim into the bearing inner race. (f) Remove the SST from the knuckle. (g) Install the 4 cone washers and nuts. Torque: 96 N·m (980 kgf·cm, 71 ft·lbf) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SA−18 SUSPENSION AND AXLE (h) 90° R13138 − STEERING KNUCKLE AND AXLE SHAFT Install the 2 plate washers and bolts. Torque: 96 N·m (980 kgf·cm, 71 ft·lbf) 6. MEASURE BEARINGS PRELOAD Using a spring tension gauge, measure the preload. Preload (at starting): 25 − 44 N (2.5 − 4.5 kgf, 5.6 − 9.9 lbf) 7. ADJUST BEARING PRELOAD (a) Remove the bearing cap and knuckle arm (See page SA−13). (b) Select the adjusting shim. Adjusting shim thickness Thickness mm (in.) Thickness mm (in.) 0.1 (0.004) 0.5 (0.020) 0.2 (0.008) 1.0 (0.039) (c) Install the bearing cap and knuckle arm (See page SA−17). 8. CONNECT TIE ROD TO KNUCKLE ARM Torque the nut and secure it with a new cotter pin. Torque: 91 N·m (925 kgf·cm, 67 ft·lbf) 9. INSTALL OIL SEAL END RETAINER TO KNUCKLE ARM Install the oil seal end retainer to steering knuckle with the 6 bolts. Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf) 10. INSTALL AXLE SHAFT Position one flat part of the outer shaft upward and install the shaft. 11. Molybdenum Disulfide Lithium Base Grease NIGI No.2 Z15222 PACK MOLYBDENUM DISULFIDE LITHIUM BASE GREASE, NLGI NO.2 Pack molybdenum disulfide lithium base grease, NLGI No.2 into the knuckle to about 3 fourths of the knuckle. 12. INSTALL KNUCKLE SPINDLE, DUST COVER WITH GASKETS AND DUST SEAL (a) Place a new gasket in the position on the knuckle and install the spindle. (b) Place the dust cover, dust seal and a new gasket on the spindle. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SA−19 SUSPENSION AND AXLE − STEERING KNUCKLE AND AXLE SHAFT (c) Torque the 8 bolts. Torque: 47 N·m (475 kgf·cm, 34 ft·lbf) 13. CONNECT ABS SPEED SENSOR Connect the speed sensor and 2 bolts to the steering knuckle. Torque: 18 N·m (185 kgf·cm, 13 ft·lbf) 14. INSTALL AXLE HUB (See page SA−9) 15. CHECK FRONT WHEEL ALIGNMENT (See page SA−4) 16. CHECK ABS SPEED SENSOR SIGNAL (See page DI−190) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SA−20 SUSPENSION AND AXLE − FRONT DIFFERENTIAL REAR OIL SEAL FRONT DIFFERENTIAL REAR OIL SEAL SA1UJ−01 COMPONENTS 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 877 Brought to you by BirfMark SA−21 SUSPENSION AND AXLE − FRONT DIFFERENTIAL REAR OIL SEAL REPLACEMENT SA1UK−01 1. 2. DRAIN DIFFERENTIAL OIL REMOVE FRONT PROPELLER SHAFT (See page PR−3) 3. (a) REMOVE COMPANION FLANGE Using a chisel and hammer, loosen the staked part of the nut. Using SST to hold the flange, remove the nut and plate washer. SST 09330−00021 SST (b) Z15176 SST (c) Using SST, remove the companion flange. SST 09950−30010 (09951−03010, 09953−03010, 09954−03010, 09955−03030, 09956−03020) 4. (a) REMOVE OIL SEAL AND OIL SLINGER Using SST, remove the oil seal. SST 09308−10010 Remove the oil slinger. R13186 SST (b) SA1973 5. REMOVE REAR BEARING Using SST, remove the rear bearing from the drive pinion. SST 09556−22010 SST SA1969 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SA−22 SUSPENSION AND AXLE − FRONT DIFFERENTIAL REAR OIL SEAL 6. REMOVE REAR BEARING OUTER RACE Using SST, remove the bearing outer race. SST 09308−00010 NOTICE: Do not scratch the taper surface of the outer race. SST SA2430 7. REMOVE OIL STORAGE RING Using a screwdriver, bend the oil storage ring and drive it out. 8. REMOVE BEARING SPACER SA2271 9. INSTALL BEARING SPACER 10. INSTALL OIL STORAGE RING Using SST, install a new oil storage ring. SST 09316−60011 (09316−00011, 09316−00021) 11. INSTALL REAR BEARING (a) Using SST, install the bearing outer race. SST 09316−60011 (09316−00011, 09316−00021) (b) Install the rear bearing. Oil Storage Ring Rear Bearing SST SST R13155 12. (a) (b) SST (c) 1.0 mm (10.039 in.) INSTALL OIL SLINGER AND OIL SEAL Install the oil slinger. Using SST, install a new oil seal, as shown. SST 09214−76011 Oil seal drive in depth: 1.0 mm (0.039 in.) Coat the lip of the oil seal with MP grease. SA2411 13. (a) SST (b) INSTALL COMPANION FLANGE Using SST, install the companion flange on the drive pinion. SST 09950−30010 (09951−03010, 09953−03010, 09954−03010, 09955−03030, 09956−03020) Place the plate washer on the companion flange. R13139 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SA−23 SUSPENSION AND AXLE (c) SST (d) 14. SA1960 15. 16. 17. Filler Hole Oil 0 − 5 mm (0 − 0.20 in.) RA1072 − FRONT DIFFERENTIAL REAR OIL SEAL Apply light coat of gear oil on threads of a new companion flange nut. Using SST to hold the flange, torque the nut. SST 09330−00021 Torque: 196 N·m (2,000 kgf·cm, 145 ft·lbf) ADJUST DRIVE PINION PRELOAD (See page SA−36) STAKE DRIVE PINION NUT INSTALL FRONT PROPELLER SHAFT (See page PR−5) FILL DIFFERENTIAL WITH GEAR OIL Torque: 49 N·m (500 kgf·cm, 39 ft·lbf) Oil type: Hypoid gear oil API GL−5 Recommended oil viscosity: Above −18°C (0°F) SAE 90 Below −18°C (0°F) SAE 80W−90 or 80W Capacity: w/o Differential lock: 2.80 liters (2.9 US qts, 2.5 Imp. qts) w/ Differential lock: 2.65 liters (2.8 US qts, 2.3 Imp. qts) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SA−24 SUSPENSION AND AXLE − FRONT DIFFERENTIAL CARRIER FRONT DIFFERENTIAL CARRIER SA1UL−01 COMPONENTS 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 881 Brought to you by BirfMark SA−25 − SUSPENSION AND AXLE FRONT DIFFERENTIAL CARRIER w/o Differential Lock Side Gear Thrust Washer Pinion Gear Pinion Gear Pinion Shaft Straight Pin Adjusting Nut Pinion Gear Thrust Washer Side Baring Outer Race z Bearing Spacer Differential Case Pinion Washer Ring Gear Drive Pinion x 10 Outer Race x5 Front Bearing z Lock Plate z Dust Deflector Oil Slinger Bearing Cap z Oil Storage Ring z Outer Race z Oil Seal Companion Flange Rear Bearing z Adjusting Nut Lock Differential Carrier z Non−reusable part W00530 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 882 Brought to you by BirfMark SA−26 SUSPENSION AND AXLE − FRONT DIFFERENTIAL CARRIER w/ Differential Lock L Straight Screw Plug Spring Seat Compression Spring Indicator Switch Ball z Gasket L Actuator z O−Ring L Shaft Retainer z Slotted Spring Pin z Dust Deflector Shift Fork Shaft z Oil Storage Ring Oil Slinger Shift Fork Differential Carrier Bearing Cap z Adjusting Nut Lock Companion Flange Outer Race Sleeve z Oil Seal Rear Bearing Side Baring z Bearing Spacer Front Bearing Outer Race LH Differential Case RH Differential Case x8 Adjusting Nut Drive Pinion Outer Race Ring Gear x8 z Lock Plate x4 Pinion Washer Pinion Gear Adjusting Nut Pinion Gear Thrust Washer Side Gear Thrust Washer Spider Side Gear z Non−reusable part L Precoated part W00531 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 883 Brought to you by BirfMark SA−27 SUSPENSION AND AXLE − FRONT DIFFERENTIAL CARRIER REMOVAL 1. (a) (b) (c) (d) (e) 2. 3. 4. 5. 6. SA1UM−03 w/ DIFFERENTIAL LOCK: BEFORE REMOVAL, SHIFT FRONT DIFFERENTIAL TO LOCK Turn the ignition switch to the ON position. Keep the center differential lock condition. Turn the differential lock control switch to the FR/RR position and lock the front differential. Rotating the tires, check they are in the differential lock condition. Disconnect the cable from the negative terminal of the battery. DRAIN DIFFERENTIAL OIL REMOVE FRONT AXLE SHAFTS (See page SA−13) REMOVE TIE ROD FROM KNUCKLE ARM (See page SA−13) REMOVE FRONT PROPELLER SHAFT (See page PR−3) w/ DIFFERENTIAL LOCK: DISCONNECT CONNECTORS AND TUBE HINT: S FA2038 S When connecting the tube of the harness side to the hose of the actuator side, its depth of insertion is 15 mm (0.59 in.). Take care that water or equivalent does not adhere to the connector and hose. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SA−28 SUSPENSION AND AXLE − FRONT DIFFERENTIAL CARRIER 7. (a) REMOVE DIFFERENTIAL CARRIER ASSEMBLY Remove the 10 nuts, washers and differential carrier assembly. NOTICE: Be careful not to damage the installation surface. Torque: 27 N·m (280 kgf·cm, 20 ft·lbf) (b) Remove the gasket. w/o Differential Lock w/ Differential Lock Z10092 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SA−29 SUSPENSION AND AXLE − FRONT DIFFERENTIAL CARRIER DISASSEMBLY SA1UN−03 1. CHECK RUNOUT OF COMPANION FLANGE Using a dial indicator, measure the vertical and lateral runout of the companion flange. Maximum runout: 0.10 mm (0.0039 in.) 30 mm (1.18 in.) W00493 2. CHECK RING GEAR RUNOUT Using a dial indicator, measure the ring gear runout. Maximum runout: 0.10 mm (0.0039 in.) If the runout is greater than the maximum, replace the ring gear and driven pinion as a set. SA2465 3. CHECK RING GEAR BACKLASH Using a dial indicator, measure the ring gear backlash. Backlash: 0.13−0.18 mm (0.0051−0.0071 in.) If the backlash is not within the specification, adjust the side bearing preload or repair as necessary. SA2462 SA2403 4. MEASURE DRIVE PINION PRELOAD Using a torque wrench, measure the preload of backlash between the drive pinion and ring gear. Preload (at starting): 0.5 − 0.8 N·m (5 − 8 kgf·cm, 4.3 − 6.9 in.·lbf) 5. CHECK TOTAL PRELOAD Using a torque wrench, measure the preload. Total preload (at starting): Drive pinion preload plus 0.4 − 0.6 N·m (4 − 6 kgf·cm, 3.5 − 5.2 in.·lbf) If necessary, disassemble and inspect the differential. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SA−30 SUSPENSION AND AXLE − FRONT DIFFERENTIAL CARRIER 6. SA2442 w/o DIFFERENTIAL LOCK: CHECK SIDE GEAR BACKLASH Using a dial indicator, measure the side gear backlash with holding one pinion gear toward the case. Backlash: 0.05 − 0.20 mm (0.0020 − 0.0079 in.) If the backlash is not within the specification, install the correct thrust washers (See page .SA−35). 7. CHECK TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION (See page SA−35) 8. w/ DIFFERENTIAL LOCK: REMOVE ACTUATOR (a) Remove the bolt and actuator from the differential carrier. (b) Remove the O−ring. 9. w/ DIFFERENTIAL LOCK: REMOVE INDICATOR SWITCH Remove the indicator switch and gasket. 10. (a) (b) w/ DIFFERENTIAL LOCK: REMOVE SHIFT FORK SHAFT Using a hexagon wrench, remove the 2 straight screw plugs. Remove the spring seat, compression spring and ball. R13332 (c) Using a pin punch and hammer, remove the slotted spring pin. SA2206 (d) Remove the 2 bolts from the shaft retainer. (e) Using a plastic hammer, tap out the shaft retainer. (f) Remove the shift fork shaft. HINT: Pull out the shift fork shaft with a screwdriver turned round. Z10098 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SA−31 SUSPENSION AND AXLE SST − FRONT DIFFERENTIAL CARRIER 11. (a) (b) REMOVE COMPANION FLANGE Using a chisel and hammer, unstake the nut. Using SST to hold the flange, remove the nut and plate washer. SST 09330−00021 (c) Using SST, remove the companion flange. SST 09950−30010 (09951−03010, 09953−03010, 09954−03010, 09955−03030, 09956−03020) 12. (a) REMOVE OIL SEAL AND OIL SLINGER Using SST, remove the oil seal from the differential carrier. SST 09308−10010 Remove the oil slinger. SA2405 SST R13141 SST (b) SA2402 13. REMOVE REAR BEARING Using SST, remove the rear bearing from the drive pinion. SST 09556−22010 SST Z00641 14. (a) (b) (c) (d) Matchmarks (e) R13142 REMOVE DIFFERENTIAL CASE Place matchmarks on the bearing cap and differential carrier. Remove the 2 adjusting nut locks. Remove the 4 bolts and 2 bearing caps. w/o Differential lock: Remove the 2 adjusting nuts. w/o Differential lock: Remove the differential case with the side bearing outer races from the carrier. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SA−32 SUSPENSION AND AXLE − FRONT DIFFERENTIAL CARRIER HINT: Tag the disassembled parts to show the location for reassembly. (f) w/ Differential lock: Remove the differential case with the side bearing outer race, adjusting nuts and sleeve from the differential carrier. (g) w/ Differential lock: Remove the shift fork. 15. REMOVE DRIVE PINION AND BEARING SPACER (a) Remove the drive pinion with the front bearing. (b) Remove the bearing spacer. 16. (a) SST REMOVE DRIVE PINION FRONT BEARING Using SST and a press, remove the bearing from the drive pinion. SST 09950−00020 HINT: If the drive pinion or ring gear are damaged, replace them as a set. (b) Remove the plate washer from the drive pinion. FA2045 Rear Bearing Outer Race 17. SST (a) REMOVE FRONT AND REAR BEARING OUTER RACES AND OIL STORAGE RING Using SST, remove the rear bearing outer race. SST 09308−00010 SA2431 Oil Strage Ring (b) Front Bearing Outer Race Using a brass bar and hammer, remove the oil storage ring and front bearing outer race. HINT: Do not remove the oil storage ring unless replacing it with a new one. SA2410 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SA−33 SUSPENSION AND AXLE − FRONT DIFFERENTIAL CARRIER 18. (a) (b) (c) (d) REMOVE RING GEAR Using a screwdriver and hammer, unstake the lock plate. Place matchmarks on the ring gear and differential case. Remove the ring gear 10 set bolts and 5 lock plates. Using a plastic hammer, tap on the ring gear to separate it from the differential case. 19. (a) CHECK DIFFERENTIAL CASE RUNOUT Install the differential case in the differential carrier and tighten the adjusting nut just to where there is no play in the bearing. Using a dial indicator, measure the differential case runout. Maximum case runout: 0.07 mm (0.0028 in.) Remove the differential case. Matchmarks Z15178 (b) (c) SA2464 20. SST W03472 REMOVE SIDE BEARING FROM DIFFERENTIAL CASE Using SST, pull the side bearing from the differential case. SST 09950−40010 (09951−04010, 09952−04020, 09953−04020, 09954−04010, 09955−04010, 09957−04010, 09958−04010), 09950−60010 (09951−00480) HINT: Fix the claws of SST to the notches in the differential case. 21. (a) (b) RA0997 22. (a) (b) (c) (d) Matchmarks FA2046 w/o DIFFERENTIAL LOCK: DISASSEMBLE DIFFERENTIAL CASE Using a pin punch and hammer, remove the straight pin. Remove these parts from the differential case: S Pinion shaft S 2 Pinion gears S 2 Pinion gear thrust washers S 2 Side gears S 2 Side gear thrust washers w/ DIFFERENTIAL LOCK: DISASSEMBLE DIFFERENTIAL CASE Place matchmarks on the LH and RH cases. Remove the 8 bolts uniformly, a little at a time. Using a plastic hammer, separate the LH and RH cases. Remove these parts from the RH differential case: S 2 Side gears S 2 Side gear thrust washers S Spider 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SA−34 SUSPENSION AND AXLE S S − FRONT DIFFERENTIAL CARRIER 4 Pinion gears 4 Pinion gear thrust washers 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SA−35 SUSPENSION AND AXLE − FRONT DIFFERENTIAL CARRIER REPLACEMENT SST SA1UO−01 1. REMOVE DUST DEFLECTOR TO COMPANION FLANGE Using SST and a press, remove the dust deflector. SST 09950−00020 SA2419 2. INSTALL DUST DEFLECTOR TO COMPANION FLANGE Using SST and a press, install a new dust deflector. SST 09726−40010 SST SA2418 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SA−36 SUSPENSION AND AXLE − FRONT DIFFERENTIAL CARRIER SA1UP−03 REASSEMBLY 1. (a) (b) SA0510 w/o DIFFERENTIAL LOCK: ASSEMBLE DIFFERENTIAL CASE Apply all of the sliding and rotating sufaces with gear oil. Install the 2 thrust washers and side gears. Using the table below, select the thrust washers which will ensure that the backlash is within the specification. Try to select washers of the same size for both sides. Thrust washer thickness Thickness (c) mm (in.) Thickness mm (in.) 1.60 (0.063) .80 (0.071) 1.70 (0.067)1 − Install the 2 side gears with the side gears thrust washers, 4 pinion gears, pinion gear thrust washers and pinion shaft. HINT: Align the hole for the pinion shaft with the case hole. (d) Using a dial indicator, measure the side gear backlash with holding one pinion gear toward the case. Backlash: 0.05 − 0.20 mm (0.0020 − 0.0079 in.) If the backlash is not within the specification, install a thrust washer of different thickness. Z06893 (e) (f) Using a pin punch and hammer, install the straight pin through the holes in the differential case and pinion shaft. Using a chisel and hammer, stake the out side of the differential case pin hole. Z06894 2. (a) (b) w/ DIFFERENTIAL LOCK: INSPECT SLEEVE Install the sleeve to the differential case (LH) and check it moves smoothly. Install the sleeve to the side gear check it moves smoothly. R08149 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SA−37 SUSPENSION AND AXLE − FRONT DIFFERENTIAL CARRIER 3. w/ DIFFERENTIAL LOCK: MEASURE CLEARANCE OF SHIFT FORK AND SLEEVE Using a feeler gauge, measure the clearance between the shift fork and sleeve. Clearance: 0.15 − 0.35 mm (0.006 − 0.014 in.) SA1987 4. (a) (b) (c) (d) (e) w/ DIFFERENTIAL LOCK: ASSEMBLE DIFFERENTIAL CASE Apply all of the sliding and rotating sufaces with gear oil. Install the side gear thrust washer to the side gear. Install the side gear to the RH case. Install the 4 pinion gears and pinion gear thrust washers to the spider. Install the pinion gear with the spider to the RH case. SA1978 (f) Using a dial indicator, holding the side gear and spider and measure the side gear backlash. Backlash: 0.05 − 0.20 mm (0.0020 − 0.0079 in.) HINT: Measure at all 4 locations. Measure the backlash at the RH case and at the LH case. If the backlash is not within the specification, install a thrust washer of a different thickness. Thrust washer thickness S S SA1976 Thickness (g) (h) (i) (j) (k) mm (in.) Thickness mm (in.) 0.9 (0.035) 1.2 (0.047) 1.0 (0.039) 1.3 (0.051) 1.1 (0.043) − Install the side gear and side gear thrust washer to the RH case. Install the pinion gears and spider to the RH case. Install the side gear and side gear thrust washer to the RH case. Align the matchmarks on the LH and RH cases. Torque the 8 bolts uniformly, a little at a time. Torque: 47 N·m (480 kgf·cm, 35 ft·lbf) FA2037 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SA−38 SUSPENSION AND AXLE 5. S S − FRONT DIFFERENTIAL CARRIER INSTALL SIDE BEARINGS w/o Differential lock: Using SST and a press, install the 2 side bearings on the differential case. SST 09950−60010 (09951−00480) w/ Differential lock: Using SST and a press, install the 2 side bearings on the differential case. SST 09223−15020, 09950−60010 (09951−00480) 6. (a) Boiling Water SA2160 INSTALL RING GEAR ON DIFFERENTIAL CASE Clean the contact surfaces of the differential case and ring gear. (b) Heat the ring gear to about 100°C (212°F) in boiling water. (c) Carefully remove the ring gear from the water. (d) After the moisture on the ring gear has completely evaporated, quickly install the ring gear to the differential case. (e) Align the matchmarks on the ring gear and differential case. (f) Temporarily install new 5 lock plates and 10 set bolts. NOTICE: The ring gear set bolts should not tighten until the ring gear has cooled sufficiently. (g) After the ring gear cools down enough, tighten the set bolts uniformly and a little at a time. Torque: 97 N·m (985 kgf·cm, 71 ft·lbf) SA2178 (h) Using a drift punch and hammer, stake the lock plates. HINT: Stake one claw flush with the flat surface of the bolt. For the claw contacting the protruding portion of the bolt, stake only the half on the tightening side. SA2182 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SA−39 SUSPENSION AND AXLE 7. (a) (b) (c) − FRONT DIFFERENTIAL CARRIER CHECK RING GEAR RUNOUT Install the differential case onto the carrier and tighten the adjusting nut just to where there is no play in the bearings. Using a dial indicator, check the ring gear runout. Maximum runout: 0.10 mm (0.0039 in.) Remove the differential case. SA2465 8. INSTALL OIL STORAGE RING Using SST and a hammer, install a new oil storage ring. SST 09316−60011 (09316−00011, 09316−00021) SST SA2406 Rear 9. Front SST SST S S INSTALL DRIVE PINION FRONT AND REAR BEARING OUTER RACES Front side: Using SST and a press, install the 2 outer races. SST 09316−60011 (09316−00011, 09316−00051) Rear side: Using SST and a press, install the 2 outer races. SST 09316−60011 (09316−00011, 09316−00021) SA2203 10. (a) SST (b) INSTALL DRIVE PINION FRONT BEARING Install the plate washer on the drive pinion with the chamfered end facing the pinion gear. Using SST and a press, install the front bearing onto the drive pinion. SST 09506−30012 FA2042 11. TEMPORARILY ADJUST DRIVE PINION PRELOAD (a) Install the drive pinion, rear bearing and oil slinger. HINT: Assemble the spacer and oil seal after adjusting the gear contact pattern. (b) Install the companion flange with SST. SST 09550−30010 (09951−03010, 09953−03010, 09954−03010, 09955−03030, 09956−03020) SST R13140 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SA−40 SUSPENSION AND AXLE − FRONT DIFFERENTIAL CARRIER (c) Adjust the drive pinion preload by tightening the companion flange nut. Using SST to hold the flange, tighten the nut. SST 09330−00021 NOTICE: As there is no spacer, tighten a little at a time, being careful not to overtighten. SST SA2401 (d) SA2403 Using a torque wrench, measure the preload. Preload (at starting): New bearing 0.9 − 1.6 N·m (10 − 16 kgf·cm, 8.7 − 13.9 in.·lbf) Reused bearing 0.5 − 0.8 N·m (5 − 8 kgf·cm, 4.3 − 6.9 in.·lbf) HINT: Measure the total preload after first turning the bearing clockwise and counterclockwise several times to mark the bearing smooth. 12. w/o DIFFERENTIAL LOCK: INSTALL DIFFERENTIAL CASE IN CARRIER (a) Place the bearing outer races on their respective bearings. Make sure the left and right outer races are not interchanged. (b) Install the case in the carrier. HINT: Make sure that there is backlash between the ring gear and drive pinion. 13. (a) (b) w/ DIFFERENTIAL LOCK: INSTALL DIFFERENTIAL CASE IN CARRIER Apply MP grease on the rack of the shift fork and connecting part of the indicator switch. Insert the shift fork into the differential carrier, as shown. MP Grease SA2161 (c) Install outer races, adjusting nuts and left side to sleeve. HINT: Check that the sleeve moves smoothly. (d) Install the shift fork in the groove of the sleeve holding it by hand and install the case in the carrier. HINT: Make sure that there is backlash between the ring gear and drive pinion. Z10100 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SA−41 SUSPENSION AND AXLE − FRONT DIFFERENTIAL CARRIER 14. w/o DIFFERENTIAL LOCK: INSTALL ADJUSTING NUTS Install the adjusting nuts on the carrier, making sure the nuts are threaded properly. Z06898 Matchmarks 15. INSTALL BEARING CAPS Align the matchmarks on the cap and carrier. Screw in the 2 bearing cap bolts 2 or 3 turns and press down the bearing cap by hand. HINT: If the bearing cap does not fit tightly on the carrier, the adjusting nuts are not threaded properly. Reinstall the adjusting nuts if necessary. SA2458 16. (a) (b) (c) SST SA2467 (d) SST ADJUST SIDE BEARING PRELOAD Torque the 4 bearing cap bolts to the specified torque, and loosen them to the point where the adjusting nuts can be turned by SST. SST 09504−00011 Torque: 78 N·m (800 kgf·cm, 58 ft·lbf) Fully tighten the 4 bearing cap bolts by hand. Using the SST, torque the adjusting nut on the ring gear side until the ring has a backlash of about 0.2 mm (0.008 in.). With turning the ring gear, use the SST to fully tighten the adjusting nut on the drive pinion side. After the bearings are settled, loosen the adjusting nut on the drive pinion side. Z10281 (e) (f) (g) Place a dial indicator on the top of the adjusting nut on the ring gear side. Adjust the side bearing for zero preload by tightening the other adjusting nut until the pointer on the indicator begins to move. Torque the adjusting nut 1 − 1.5 notches from the zero preload position. SA2308 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SA−42 SUSPENSION AND AXLE (h) SST SA2443 − FRONT DIFFERENTIAL CARRIER Using a dial indicator, adjust the ring gear backlash until it is within the specification. Backlash: 0.13 − 0.18 mm (0.0051 − 0.0071 in.) HINT: The backlash is adjusted by turning the left and right adjusting nuts equal amounts. For example, loosen the nut on the left side one notch and torque the nut on the right side one notch. (i) Torque the 4 bearing cap bolts. Torque: 78 N·m (800 kgf·cm, 58 ft·lbf) (j) (k) Recheck the ring gear backlash. Backlash: 0.13−0.18 mm (0.0051−0.0071 in.) Using a torque wrench, measure the preload. Total preload (at starting): Drive pinion preload plus 0.4 − 0.6 N·m (4 − 6 kgf·cm, 3.5 − 5.2 in.·lbf) SA2403 17. (a) (b) (c) INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION Coat 3 or 4 teeth at 3 different positions on the ring gear with red lead. Hold the companion flange firmly and rotate the ring gear in both directions. Inspect the tooth pattern. SA2463 Heel Contact Face Contact Proper Contact Select an adjusting washer that will bring the drive pinion closer to the ring gear. Flank Contact Toe Contact Select an adjusting washer that will shift the drive pinion away from the ring gear. FA2013 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SA−43 SUSPENSION AND AXLE − FRONT DIFFERENTIAL CARRIER If the teeth are not contacting properly, use the following chart to select a proper washer for correction. Washer thickness Thickness Washer FA2041 mm (in.) Thickness mm (in.) 1.70 (0.0669) 2.03 (0.0799) 1.73 (0.0681) 2.06 (0.0811) 1.76 (0.0693) 2.09 (0.0823) 1.79 (0.0705) 2.12 (0.0835) 1.82 (0.0717) 2.15 (0.0846) 1.85 (0.0728) 2.18 (0.0858) 1.88 (0.0740) 2.21 (0.0870) 1.91 (0.0752) 2.24 (0.0882) 1.94 (0.0764) 2.27 (0.0894) 1.97 (0.0776) 2.30 (0.0906) 2.00 (0.0787) 2.33 (0.0917) 18. REMOVE COMPANION FLANGE (See page SA−29) 19. 20. REMOVE OIL SLINGER AND REAR BEARING REMOVE REAR BEARING OUTER RACE AND OIL STORAGE RING (See page SA−29) INSTALL BEARING SPACER AND REAR BEARING Install a new bearing spacer on the shaft. Install a new oil storage ring and rear bearing outer race (See page SA−29). Install the rear bearing and oil slinger. 21. (a) (b) (c) W00529 22. (a) (b) INSTALL OIL SEAL Using SST, install a new oil seal, as shown. SST 09214−76011 Oil seal drive in depth: 1.0 mm (0.039 in.) Apply MP grease to the oil seal lip. SST SA2407 23. (a) SST INSTALL COMPANION FLANGE Install the companion flange with SST. SST 09550−30010 (09951−03010, 09953−03010, 09954−03010, 09955−03030, 09956−03020) R13140 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SA−44 SUSPENSION AND AXLE − FRONT DIFFERENTIAL CARRIER (b) Install the plate washer and a new nut. HINT: Coat the threads of a new nut with gear oil. (c) Using SST to hold the flange, tighten the nut. SST 09330−00021 Torque: 196 N·m (2,000 kgf·cm, 145 ft·lbf) SST SA2390 SA2403 24. ADJUST DRIVE PINION PRELOAD Using a torque wrench, measure the preload of the backlash between the drive pinion and ring gear. Preload (at starting): New bearing: 0.9 − 1.6 N·m (10 − 16 kgf·cm, 8.7 − 13.9 in.·lbf) Reused bearing: 0.5 − 0.8 N·m (5 − 8 kgf·cm, 4.3 − 6.9 in.·lbf) If the preload is greater than the specification, replace the bearing spacer. If the preload is less than the specification, retighten the nut a little at a time with a torque of 13 N·m (130 kgf·cm, 9 ft·lbf) until the specified preload is reached. Maximum torque: 343 N·m (3,500 kgf·cm, 253 ft·lbf) If the maximum torque is exceeded while retightening the nut, replace the bearing spacer and repeat the preload procedure. Do not back off the pinion nut to reduce the preload. 25. RECHECK RING GEAR BACKLASH 26. RECHECK TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION 27. CHECK RUNOUT OF COMPANION FLANGE 28. STAKE DRIVE PINION NUT 29. (a) (b) INSTALL ADJUSTING NUT LOCKS Install 2 new nut locks on the bearing caps. Torque: 13 N·m (130 kgf·cm, 9 ft·lbf) After tightening bolts, bend the nut locks. SA2471 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SA−45 SUSPENSION AND AXLE 30. Holes (a) (b) Groore − FRONT DIFFERENTIAL CARRIER w/ DIFFERENTIAL LOCK: INSTALL SHIFT FORK SHAFT Apply MP grease onto the outer circuit of the fork shaft. Install the fork shaft to match the hole of the shift fork and that of the shift fork shaft. SA2417 (c) FIPG Width Approx. 1 − 2 mm (0.04 − 0.08 in.) (d) Remove any FIPG material and be careful not to drop oil on the contacting surface of the differential carrier and shaft retainer. Apply FIPG to the carrier, as shown. FIPG: Part No. 08826−00090, THREE BOND 1281 or equivalent HINT: Install the shaft retainer within 10 minutes after applying FIPG. Z15179 (e) (f) (g) Adhesive Clean the threads of the bolts and retainer bolts holes with toluene or trichlorethylene. Apply adhesive to 2 or 3 threads of the mount bolt end. Adhesive: Part No. 08833−00080, THREE BOND 1344, LOCTITE 242 or equivalent Tighten the shaft retainer with the 2 bolts. Torque: 24 N·m (240 kgf·cm, 17 ft·lbf) Z10101 (h) Using a pin punch and hummer, install the slotted spring pin to the shift fork. (i) Shift the fork deeply and keep the differential lock condition. SA2205 Lock SA1979 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SA−46 SUSPENSION AND AXLE (j) (k) (l) (m) R13413 − FRONT DIFFERENTIAL CARRIER Install the ball, compression spring and spring seat. Clean the threads of 2 plugs and plug holes with toluene or trichloroethylene. Apply adhesive to the plug threads. Adhesive: Part No. 08833−00080, THREE BOND 1344, LOCTITE 242 or equivalent Using a hexagon wrench, install and tighten the screw plugs. Torque: 22 N·m (220 kgf·cm, 16 ft·lbf) 31. w/ DIFFERENTIAL LOCK: MEASURE DISTANCE BETWEEN SLEEVE AND DIFFERENTIAL CASE END SIDE Measure distance between the sleeve and tip of the differential case when differential is free and locked. Standard distance: LOCK: 17.44 − 18.86 mm (0.6866 − 0.7425 in.) FREE: 32.40 − 33.90 mm (1.2756 − 1.3346 in.) R08152 32. w/ DIFFERENTIAL LOCK: INSTALL INDICATOR SWITCH Install the indicator switch with a new gasket. Torque: 40 N·m (410 kgf·cm, 30 ft·lbf) SA1993 33. (a) Outside Shift Fork w/ DIFFERENTIAL LOCK: INSTALL ACTUATOR Check that the outermost rack tooth of the shift fork is virtually above the center line of the actuator installation hole. Actuator Installation Hole R08153 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SA−47 SUSPENSION AND AXLE − FRONT DIFFERENTIAL CARRIER (b) 3 2 1.5 V Ensure that the matchmarks of the pinion of the actuator is in the extent between zero and 5 degrees clockwise above the center line of the actuator. If the matchmarks is not in this extent, rotate the pinion to be matched. Do not supply the battery positive voltage directly between terminals. If the matchmarks come to the extension limit of the rotation, do not electrify moreover. 5° 108° Matchmark (Groove) R08154 (c) (d) (e) Install a new O−ring to the actuator. Apply a light coat of gear oil on the O−ring. Apply MP grease to the gear part. (f) Insert the actuator so that the long hole on the actuator side fits with the knock pin on the carrier side. SA2306 HINT: Do not damage the O−ring of the actuator. (g) Align the actuator with the long hole and rotate the actuator counterclockwise when the knock pin reaches the right−hand side. SA1992 (h) Install the actuator to the differential carrier with the bolt so that the outermost rack tooth of the shift fork will fit the matchmarks of the pinion of the actuator. Torque: 26 N·m (270 kgf·cm, 20 ft·lbf) R08218 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SA−48 SUSPENSION AND AXLE − FRONT DIFFERENTIAL CARRIER SA1UQ−01 INSTALLATION Installation is in the reverse order of removal (see page SA−27). HINT: S w/ differential lock: Before installation, check differential lock operation connecting the connector of the actuator to the connector of the vehicle side. S w/ differential lock: Before installation, check that the sleeves on work with switching over the differential lock control switch. After checking, lock the front differential. S After installation, fill the differential with gear oil (See page SA−27). S w/ differential lock: After installation, check that the bleeder plug at the point of the bleeder tube (inside of the engine room) is not damaged or worn. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SA−49 SUSPENSION AND AXLE − COIL SPRING AND FRONT SHOCK ABSORBER COIL SPRING AND FRONT SHOCK ABSORBER SA1UR−01 COMPONENTS 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 906 Brought to you by BirfMark SA−50 SUSPENSION AND AXLE − COIL SPRING AND FRONT SHOCK ABSORBER REMOVAL SA1US−01 1. REMOVE FRONT WHEEL Torque: Steel wheel: 147 N·m (1,500 kgf·cm, 109 ft·lbf) Aluminum wheel: 103 N·m (1,050 kgf·cm, 76 ft·lbf) 2. (a) (b) REMOVE FRONT SHOCK ABSORBER Jack up and support the axle housing. Hold the piston rod and remove the upper mounting nut. Torque: 69 N·m (700 kgf·cm, 51 ft·lbf) (c) Hold the shock absorber and remove the lower mounting nut, shock absorber, cushions and retainers. Torque: 69 N·m (700 kgf·cm, 51 ft·lbf) DISCONNECT STABILIZER BAR FROM AXLE HOUSING (See page SA−60) REMOVE COIL SPRING Jack down and support axle housing. SA2662 3. 4. (a) SA2663 (b) R13152 Using SST, compress the coil spring. SST 09727−30021 NOTICE: Do not use an impact wrench. It will damage the SST. (c) Remove the coil spring. HINT: Align the coil spring end with the lower seat and install the coil spring. 5. REMOVE FOLLOW SPRING Remove the 2 nuts and follow spring. Torque: 9.2 N·m (94 kgf·cm, 82 in.·lbf) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SA−51 SUSPENSION AND AXLE − COIL SPRING AND FRONT SHOCK ABSORBER INSPECTION FA0530 SA1UT−01 INSPECT SHOCK ABSORBER Compress and extend the shock absorber rod and check that there is abnormal resistance or unusual operation sounds. If there is any abnormality, replace the shock absorber with a new one. NOTICE: When discarding the shock absorber, use the following procedure. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SA−52 SUSPENSION AND AXLE − COIL SPRING AND FRONT SHOCK ABSORBER DISPOSAL 50 mm (1.97 in.) 30 mm (1.18 in.) SA1UU−01 DISCARD SHOCK ABSORBER Before discarding the shock absorber, drill a hole 2 − 3 mm (0.079 − 0.118 in.) in diameter at the location shown in the illustration to release the gas inside. NOTICE: When drilling, chips may fly out, work carefully. The gas is colorless, odorless and non−poisonous. SA2667 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SA−53 SUSPENSION AND AXLE − COIL SPRING AND FRONT SHOCK ABSORBER SA1UV−01 INSTALLATION Installation is in the reverse order of removal (See page SA−50). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SA−54 SUSPENSION AND AXLE − FRONT LATERAL CONTROL ROD FRONT LATERAL CONTROL ROD SA1UW−01 REMOVAL 1. REMOVE FRONT WHEEL Torque: Steel wheel: 147 N·m (1,500 kgf·cm, 109 ft·lbf) Aluminum wheel: 103 N·m (1,050 kgf·cm, 76 ft·lbf) 2. DISCONNECT LATERAL CONTROL ROD FROM AXLE HOUSING Remove the bolt and disconnect the lateral control rod from the axle housing. Torque: 171 N·m (1,750 kgf·cm, 127 ft·lbf) HINT: After stabilizing the suspension, torque the bolt. SA2675 3. REMOVE LATERAL CONTROL ROD FROM FRAME Remove the nut, bolt and lateral control rod. Torque: 171 N·m (1,750 kgf·cm, 127 ft·lbf) HINT: After stabilizing the suspension, torque the bolt. SA2676 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 911 Brought to you by BirfMark SA−55 SUSPENSION AND AXLE − FRONT LATERAL CONTROL ROD REPLACEMENT SA1UX−01 1. REMOVE BUSHING Using SST, remove the bushing from the lateral control rod. SST 09710−22042 (09710−02051, 09710−02071), 09950−70010 (09951−07150) SST SST FA0533 2. INSTALL BUSHING Using SST, install a new bushing into the lateral control rod. SST 09710−22042 (09710−02051, 09710−02071) HINT: Do not use a lubricant when pressing in the bushing. SST SST FA0534 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SA−56 SUSPENSION AND AXLE − FRONT LATERAL CONTROL ROD SA1UY−01 INSTALLATION Installation is in the reverse order of removal (See page SA−54). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SA−57 SUSPENSION AND AXLE − FRONT LEADING ARM FRONT LEADING ARM REMOVAL SA1UZ−01 1. REMOVE FRONT WHEEL Torque: Steel wheel: 147 N·m (1,500 kgf·cm, 109 ft·lbf) Aluminum wheel: 103 N·m (1,050 kgf·cm, 76 ft·lbf) 2. (a) REMOVE LEADING ARM Remove the bolt, plate washer and nut from the leading arm to the frame side. Torque: 177 N·m (1,800 kgf·cm, 130 ft·lbf) HINT: After stabilizing the suspension, torque the bolt. SA2677 (b) Remove the 2 bolts and nuts from the leading arm to the axle housing side. Torque: 171 N·m (1,750 kgf·cm, 127 ft·lbf) HINT: After stabilizing the suspension, torque the bolts. (c) Remove the leading arm. SA2678 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 914 Brought to you by BirfMark SA−58 SUSPENSION AND AXLE − FRONT LEADING ARM REPLACEMENT SA1V0−02 REPLACE BUSHINGS Using SST and a press, replace the bushing from the leading arm. SST Front side: 09710−30050 SST Rear side: 09710−22042 (09710−02061) SST R13847 HINT: When assembling a new bushing, as shown in the illustration. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SA−59 SUSPENSION AND AXLE − FRONT LEADING ARM SA1V1−01 INSTALLATION Installation is in the reverse order of removal (See page SA−57). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SA−60 SUSPENSION AND AXLE − FRONT STABILIZER BAR FRONT STABILIZER BAR REMOVAL SA1V2−01 1. REMOVE FRONT WHEEL Torque: Steel wheel: 147 N·m (1,500 kgf·cm, 109 ft·lbf) Aluminum wheel: 103 N·m (1,050 kgf·cm, 76 ft·lbf) 2. (a) REMOVE STABILIZER BAR Remove the nut and disconnect the stabilizer bar with the link from the bracket. Torque: 103 N·m (1,050 kgf·cm, 76 ft·lbf) HINT: After stabilizing the suspension, torque the nut. R07756 (b) Remove the bolt and nut and remove the stabilizer bar from the axle housing. Torque: 25 N·m (260 kgf·cm, 19 ft·lbf) HINT: After stabilizing the suspension, torque the nut. R08394 (c) Paint Remove the 2 bolts, cover and cushion from the stabilizer bar. Torque: 18 N·m (185 kgf·cm, 13 ft·lbf) HINT: Install the cushions on the lines painted on the stabilizer bar and install the covers onto cushions. R13153 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 917 Brought to you by BirfMark SA−61 SUSPENSION AND AXLE − FRONT STABILIZER BAR SA1V3−01 INSTALLATION Installation is in the reverse order of removal (See page SA−60). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SA−62 SUSPENSION AND AXLE − REAR AXLE SHAFT REAR AXLE SHAFT SA1V4−01 COMPONENTS 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 919 Brought to you by BirfMark SA−63 SUSPENSION AND AXLE − REAR AXLE SHAFT REMOVAL SA1V5−01 REMOVE REAR AXLE SHAFT (a) Remove the 6 set nuts and plate washers. Torque: 34 N·m (340 kgf·cm, 25 ft·lbf) (b) Using a brass bar and hammer, strike the center part of the axle shaft to remove the 6 cone washers. (c) Install and gradually tighten 2 bolts evenly and pull the axle shaft. (d) Remove the 2 bolts from the rear axle shaft. (e) Remove the rear axle shaft and gasket. NOTICE: Be careful not to damage the oil seal. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SA−64 SUSPENSION AND AXLE − REAR AXLE SHAFT INSPECTION SA1V6−01 1. (a) (b) INSPECT REAR AXLE SHAFT Check for wear or damage. Using a dial indicator, check the runout of axle shaft. Maximum runout: 0.8 mm (0.031 in.) If the runout is greater than the maximum, replace the axle shaft. RA0377 2. (a) REPLACE OIL SEAL Using SST, remove the oil seal. SST 09308−00010 (b) Using SST and a hammer, install a new oil seal into the hub. SST 09517−36010 Apply MP grease to the oil seal lip. (c) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SA−65 SUSPENSION AND AXLE − REAR AXLE SHAFT SA1V7−02 INSTALLATION Installation is in the reverse order of removal (See page SA−63). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SA−66 SUSPENSION AND AXLE − REAR AXLE HUB REAR AXLE HUB SA1V8−01 COMPONENTS 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 923 Brought to you by BirfMark SA−67 SUSPENSION AND AXLE − REAR AXLE HUB REMOVAL SA1V9−01 1. 2. 3. REMOVE REAR WHEEL REMOVE REAR AXLE SHAFT (See page SA−63) REMOVE BRAKE CALIPER AND DISC (See page BR−34) 4. DISCONNECT ABS SPEED SENSOR Remove the bolt and disconnect the ABS speed sensor. 5. (a) (b) 6. (a) (b) REMOVE REAR AXLE BEARING LOCK NUT Remove the 2 screws from the lock nut. Using SST, remove the lock nut. SST 09509−25011 REMOVE REAR AXLE HUB Pull out the axle hub, remove the lock nut plate and outer bearing. Remove the axle hub. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SA−68 SUSPENSION AND AXLE − REAR AXLE HUB REPLACEMENT 1. (a) (b) SA1VA−01 REMOVE OIL SEAL AND INNER BEARING Using SST, remove the oil seal. SST 09308−00010 Remove the inner bearing from the hub. 2. REMOVE BEARING OUTER RACE Using a brass bar and hammer, remove the bearing outer races. NOTICE: Be careful not to damage the ABS speed sensor rotor. Brass Bar Positions R13157 3. S SST S R13158 4. (a) (b) (c) 5. INSTALL BEARING OUTER RACE Outside race: Using SST and a press, install new bearing outer races. SST 09950−60020 (09951−00710), 09950−70010 (09951−07150) Inside race: Using SST and a press, install new bearing outer races. SST 09950−60020 (09951−00810), 09950−70010 (09951−07150) PACK BEARINGS WITH MP GREASE Place MP grease on the palm of your hand. Pack grease into the bearing until the grease ooze out from the other side. Do the same around the bearing circumference. COAT INSIDE OF HUB WITH MP GREASE R13159 6. (a) (b) (c) INSTALL INNER BEARING AND OIL SEAL Place inner bearing into the hub. Using SST, install a new oil seal into the hub. SST 09223−15020, 09950−70010 (09951−07150) Apply MP grease to the oil seal lip. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SA−69 SUSPENSION AND AXLE − REAR AXLE HUB INSTALLATION SA1VB−01 1. (a) INSTALL REAR AXLE HUB Clean the hub installation position of the axle housing and apply MP grease thinly. (b) Place the axle hub to the axle housing. NOTICE: Be careful not to damage the oil seal. (c) Install the outer bearing. 2. INSTALL LOCK NUT PLATE AND REAR AXLE BEARING LOCK NUT (a) Place the lock nut plate on the axle housing, making sure the tongue lines up with the key groove. (b) Temporarily install the lock nut. 3. INSTALL DISC Install the disc to the rear axle hub and temporarily install the 2 hub nuts. 4. (a) ADJUST PRELOAD Using SST, torque the bearing lock nut. SST 09509−25011 Torque: 59 N·m (600 kgf·cm, 43 ft·lbf) (b) Make the bearing smooth by turning the hub several times. (c) Using the SST, retighten the bearing lock nut. Torque: 59 N·m (600 kgf·cm, 43 ft·lbf) (d) Using the SST, loosen the nut until it can be turned by hand. (e) Using a spring tension gauge, check the preload and tighten the nut until the preload is within the specification. Preload (at starting): 26−57 N (2.6−5.8 kgf, 5.7−12.8 lbf) NOTICE: Make sure that there is no contact with the parking brake shoe. Lock Nut Mark (f) Align the mark on the bearing lock nut and tip of axle housing under the above preload range. Axle Housing Mark R08001 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SA−70 SUSPENSION AND AXLE − REAR AXLE HUB (g) OK −0.2 − 0.9 mm W00498 Check the distance between top surface of axle housing and the lock nut. Standard distance: −0.2 − 0.9 mm (−0.0079 − 0.0354 in.) If the distance is greater than the specification, reassemble the lock nut plate. (h) Check that the hub with disc rotates smoothly and hub has no axial play. 5. INSTALL BEARING LOCK NUT SCREW Tighten the 2 lock nut screws. Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf) 6. CONNECT ABS SPEED SENSOR Connect the ABS speed sensor install the bolt. Torque: 18 N·m (185 kgf·cm, 13 ft·lbf) 7. INSTALL BRAKE CALIPER (See page BR−38) 8. INSTALL REAR AXLE SHAFT (See page SA−65) 9. INSTALL REAR WHEEL Torque: Steel wheel: 147 N·m (1,500 kgf·cm, 109 ft·lbf) Aluminum wheel: 103 N·m (1,050 kgf·cm, 76 ft·lbf) 10. CHECK ABS SPEED SENSOR SIGNAL (See page DI−190) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SA−71 SUSPENSION AND AXLE − REAR WHEEL HUB BOLT REAR WHEEL HUB BOLT REPLACEMENT 1. SA1VC−01 REMOVE REAR AXLE HUB (See page SA−67) 2. REMOVE HUB BOLT Using SST and a press, remove hub bolt from the axle hub. SST 09950−70010 (09951−07150) NOTICE: Be careful not to damage the ABS speed sensor rotor. 3. INSTALL HUB BOLT Using SST and a press, install the hub bolt. SST 09950−70010 (09951−07150) 4. INSTALL REAR AXLE HUB (See page SA−69) 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 928 Brought to you by BirfMark SA−72 SUSPENSION AND AXLE − REAR DIFFERENTIAL FRONT OIL SEAL REAR DIFFERENTIAL FRONT OIL SEAL SA1VD−01 COMPONENTS 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 929 Brought to you by BirfMark SA−73 SUSPENSION AND AXLE − REAR DIFFERENTIAL FRONT OIL SEAL REPLACEMENT SA1VE−01 1. 2. DRAIN DIFFERENTIAL OIL DISCONNECT REAR PROPELLER SHAFT (See page PR−3) 3. (a) REMOVE COMPANION FLANGE Using a chisel and hammer, loosen the staked part of the nut. Using SST to hold the flange, remove the nut and plate washer. SST 09330−00021 (b) SST Z15218 (c) Using SST, remove the companion flange. SST 09950−30010 (09951−03010, 09953−03010, 09954−03010, 09955−03030, 09956−03020) 4. (a) REMOVE OIL SEAL AND OIL SLINGER Using SST, remove the oil seal. SST 09308−10010 Remove the oil slinger. R13239 SST (b) Z06901 5. REMOVE FRONT BEARING Using SST, remove the front bearing from the drive pinion. SST 09556−22010 SST Z06902 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SA−74 SUSPENSION AND AXLE − REAR DIFFERENTIAL FRONT OIL SEAL 6. REMOVE BEARING OUTER RACE Using SST, remove the bearing outer race. SST 09308−00010 NOTICE: Do not scratch the taper surface of the outer race. 7. REMOVE BEARING SPACER 8. INSTALL NEW BEARING SPACER SST SA2395 9. INSTALL BEARING OUTER RACE Using SST, install the bearing outer race. SST 09316−60011 (09316−00011, 09316−00021) 10. INSTALL FRONT BEARING SST Z06903 11. (a) (b) SST (c) INSTALL OIL SLINGER AND OIL SEAL Install the oil slinger. Using SST, install a new oil seal, as shown. SST 09214−76011 Oil seal drive in depth: 1.0 mm (0.039 in.) Apply MP grease to the oil seal lip. Z06904 12. (a) SST (b) (c) INSTALL COMPANION FLANGE Using SST, install the companion flange on the drive pinion. SST 09950−30010 (09951−03010, 09953−03010, 09954−03010, 09955−03030, 09956−03020) Place the plate washer on the companion flange. Apply light coat of gear oil on threads of a new companion flange nut. R13238 (d) SST 13. 14. 15. Using SST to hold the flange, torque the nut. SST 09330−00021 Torque: 245 N·m (2,500 kgf·cm, 181 ft·lbf) ADJUST DRIVE PINION PRELOAD (See page SA−73) STAKE DRIVE PINION NUT CONNECT REAR PROPELLER SHAFT (See page PR−5) SA1966 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SA−75 SUSPENSION AND AXLE 16. Less than 5 mm (10.20 in.) − REAR DIFFERENTIAL FRONT OIL SEAL FILL DIFFERENTIAL WITH GEAR OIL Torque: 49 N·m (500 kgf·cm, 39 ft·lbf) Oil type: Hypoid gear oil API GL−5 Recommended oil viscosity: Above −18°C (0°F) SAE 90 Below −18°C (0°F) SAE 80W−90 or 80W Capacity: 3.25 liters (3.4 US qts, 2.9 Imp. qts) Z06905 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SA−76 SUSPENSION AND AXLE − REAR DIFFERENTIAL CARRIER REAR DIFFERENTIAL CARRIER SA1VF−03 COMPONENTS 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 933 Brought to you by BirfMark SA−77 SUSPENSION AND AXLE − REAR DIFFERENTIAL CARRIER 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 934 Brought to you by BirfMark SA−78 SUSPENSION AND AXLE − REAR DIFFERENTIAL CARRIER 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 935 Brought to you by BirfMark SA−79 SUSPENSION AND AXLE − REAR DIFFERENTIAL CARRIER REMOVAL 1. (a) (b) (c) SA24T−01 w/ Differential lock: SHIFT REAR DIFFERENTIAL TO LOCK Turn the ignition switch to the ON position. Keep the center differential lock condition. Turn the differential lock control switch to the RR or FR/ RR position and lock the rear differential. HINT: Rotating the tires, check they are in the differential lock condition. (d) Disconnect the cable from the negative terminal of the battery. 2. DRAIN DIFFERENTIAL OIL 3. REMOVE REAR AXLE SHAFTS (See page SA−63) 4. DISCONNECT PROPELLER SHAFT (See page PR−3) 5. (a) REMOVE DIFFERENTIAL CARRIER ASSEMBLY Remove the 10 nuts, washers and differential carrier assembly. NOTICE: Be careful not to damage the installation surface. Torque: 73 N·m (740 kgf·cm, 54 ft·lbf) (b) Remove the gasket. SA2310 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SA−80 SUSPENSION AND AXLE − REAR DIFFERENTIAL CARRIER DISASSEMBLY SA1VH−04 1. CHECK RUNOUT OF COMPANION FLANGE Using a dial indicator, measure the vertical and lateral runout of the companion flange. Maximum runout: 0.10 mm (0.0039 in.) 30 mm (1.18 in.) W00493 2. CHECK RING GEAR RUNOUT Using a dial indicator, measure the ring gear runout. Maximum runout: 0.10 mm (0.0039 in.) If the runout is greater than the maximum, replace the ring gear. 3. CHECK RING GEAR BACKLASH Using a dial indicator, measure the ring gear backlash. Backlash: 0.15 − 0.20 mm (0.0059 − 0.0079 in.) HINT: Perform the measurements at 3 or more positions around the circumference of the ring gear. If the backlash is not within the specification, adjust the side bearing preload or repair as necessary. 4. (a) SA2446 MEASURE DRIVE PINION PRELOAD Using a torque wrench, measure the preload of backlash between the drive pinion and ring gear. Preload (at starting): 0.7 − 1.0 N·m (7 − 10 kgf·cm, 6.1 − 8.7 in.·lbf) (b) Using a torque wrench, measure the preload. Total preload (at starting): Drive pinion preload plus w/o Differential lock 0.4 − 0.6 N·m (4 − 6 kgf·cm, 3.5 − 5.2 in.·lbf) w/ differential lock 0.3 − 0.7 N·m (3 − 7 kgf·cm, 2.6 − 6.1 in.·lbf) If necessary, disassemble and inspect the differential. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SA−81 SUSPENSION AND AXLE − REAR DIFFERENTIAL CARRIER 5. CHECK SIDE GEAR BACKLASH Using a dial indicator, measure the side gear backlash with holding one pinion gear toward the case. Backlash: 0.02 − 0.20 mm (0.0008 − 0.0079 in.) If the backlash is not within the specification, install the correct thrust washers (See page SA−87). 6. CHECK TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION (See page SA−35) 7. w/ DIFFERENTIAL LOCK: REMOVE INDICATOR SWITCH Remove the indicator switch and gasket. 8. w/ DIFFERENTIAL LOCK: REMOVE COVER (a) Remove the 3 bolts. (b) Using a brass bar and hammer, tap on the cover to remove it. 9. (a) (b) (c) w/ DIFFERENTIAL LOCK: REMOVE SLEEVE Remove the 4 bolts. Using a plastic hammer, tap the actuator. Remove the actuator and sleeve. SA2131 10. (a) (b) w/ DIFFERENTIAL LOCK: REMOVE ACTUATOR AND SHIFT FORK AND SHAFT Remove the shift fork shaft bolt. Pull out the actuator and remove the shift fork. SA2134 11. (a) (b) SST REMOVE COMPANION FLANGE Using a chisel and hammer, unstick the nut. Using SST to hold the flange, remove the nut and plate washer. SST 09330−00021 SA2448 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SA−82 SUSPENSION AND AXLE − REAR DIFFERENTIAL CARRIER (c) Using SST, remove the companion flange. SST 09950−30010 (09951−03010, 09953−03010, 09954−03010, 09955−03030, 09956−03020) 12. (a) REMOVE OIL SEAL AND OIL SLINGER Using SST, remove the oil seal from the differential carrier. SST 09308−10010 Remove the oil slinger. SST R13166 SST (b) SA2348 13. REMOVE FRONT BEARING Using SST, remove the front bearing from the drive pinion. SST 09556−22010 If the front bearing is damaged or worn, replace the bearing. SST SST SST Z00641 14. (a) w/o DIFFERENTIAL LOCK: REMOVE DIFFERENTIAL CASE ASSEMBLY Place matchmarks on the bearing cap and differential carrier. Remove the 2 adjusting nut locks. (b) HINT: Tag the disassembled parts to show the location for reassembly. (c) Remove the 2 bearing caps and adjusting nuts. (d) Remove the differential case with the bearing outer races from the carrier. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SA−83 SUSPENSION AND AXLE 15. (a) (b) − REAR DIFFERENTIAL CARRIER w/ DIFFERENTIAL LOCK: REMOVE DIFFERENTIAL CASE ASSEMBLY Place matchmarks on the bearing cap and differential carrier. Remove the 4 bolts and 2 bearing caps. Matchmarks SA2437 (c) SST Using SST, remove the plate washers. SST 09504−22011 HINT: Measure the plate washer thickness and note it. (d) Remove the differential case with the side bearing outer races from the differential carrier. HINT: Tag the bearing outer races to show the location for reassembly. R08254 16. SST (a) (b) 17. (a) Z06911 REMOVE DRIVE PINION AND BEARING SPACER FROM DIFFERENTIAL CARRIER Remove the drive pinion with the rear bearing. Remove the bearing spacer. REMOVE DRIVE PINION REAR BEARING Using SST and a press, remove the rear bearing from the drive pinion. SST 09950−00020 HINT: If the drive pinion or ring gear are damaged, replace them as a set. (b) Remove the plate washer from the drive pinion. 18. REMOVE FRONT AND REAR BEARING OUTER RACES Using a brass bar and hammer, remove the outer races. SA2424 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SA−84 SUSPENSION AND AXLE − REAR DIFFERENTIAL CARRIER 19. (a) (b) (c) REMOVE RING GEAR Place matchmarks on the ring gear and differential case. Remove the 12 ring gear set nuts and bolts. Using a plastic hammer, tap on the ring gear to remove it from the differential case. 20. (a) CHECK DIFFERENTIAL CASE RUNOUT Install the differential case in the differential carrier and tighten the adjusting nut just to where there is no play in the bearing. Using a dial indicator, measure the differential case runout. Maximum case runout: 0.07 mm (0.0028 in.) Remove the differential case. (b) (c) SA2464 21. w/o DIFFERENTIAL LOCK: REMOVE SIDE BEARINGS FROM DIFFERENTIAL CASE Using SST, remove the 2 side bearings from the differential case. SST 09950−40010 (09951−04010, 09952−04010, 09953−04020, 09955−04060, 09957−04010, 09958−04010), 09950−60010 (09951−00480) 22. w/ DIFFERENTIAL LOCK: REMOVE SIDE BEARINGS FROM DIFFERENTIAL CASE (a) Using SST, remove the side bearing (ring gear side). SST 09950−40010 (09951−04010, 09952−04010, 09953−04020, 09955−04060, 09957−04010, 09958−04010), 09950−60010 (09951−00480) HINT: Fix the claws of SST to the notches in the differential case. (b) Using SST, 4 bolts and a press, remove the side bearing (cover side). SST 09550−10012 (09557−10010), 09950−70010 (09951−07150) HINT: Fix the claws of SST to the notches in the differential case. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SA−85 SUSPENSION AND AXLE 23. (a) (b) 24. (a) (b) SST − REAR DIFFERENTIAL CARRIER w/o DIFFERENTIAL LOCK: DISASSEMBLE DIFFERENTIAL CASE Remove the pinion shaft pin and washer. Remove these parts from the differential case: S Pinion shaft S 2 Pinion gears S 2 Pinion gear thrust washers S 2 Side gears S 2 Side gear thrust washers w/ DIFFERENTIAL LOCK: DISASSEMBLE DIFFERENTIAL CASE Place matchmarks on the case and cover. Using a torx socket wrench, remove the 5 set bolts and 3 pinion shaft pins. SA2475 (c) (d) Using the 2 cover installation bolts, separate the cover and case. Remove these parts from the differential case: S 2 Side gears S 2 Side gear thrust washers S 4 Pinion gears S 4 Pinion thrust washers S 3 Pinion shafts S Pinion shaft holder 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SA−86 SUSPENSION AND AXLE − REAR DIFFERENTIAL CARRIER REPLACEMENT SST 1. REMOVE DUST DEFLECTOR Using SST and a press, remove the dust deflector. SST 09950−00020 SA2419 2. INSTALL DUST DEFLECTOR Using SST and a press, install a new dust deflector. SST 09726−40010 SST SA2418 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 SA1VI−01 Brought to you by BirfMark SA−87 SUSPENSION AND AXLE − REAR DIFFERENTIAL CARRIER SA1VJ−04 REASSEMBLY 1. (a) (b) SA0510 w/o DIFFERENTIAL LOCK: ASSEMBLE DIFFERENTIAL CASE Apply all of the sliding and rotating surfaces with gear oil. Install the 2 thrust washers and side gears. Using the table below, select the thrust washers which will ensure that the backlash is within the specification. Try to select washers of the same size for both sides. Backlash: 0.02 − 0.20 mm (0.0008−0.0079 in.) Thrust washer thickness Thickness (c) mm (in.) Thickness mm (in.) 1.60 (0.063) 1.90 (0.075) 1.75 (0.069) 2.05 (0.081) Install the side gears with the side gear thrust washers, pinion gears, pinion gear thrust washers and pinion shaft. HINT: Align the hole for the pinion shaft and differential case hole. (d) Using a dial indicator, measure the side gear backlash with holding the one pinion gear toward the case. Backlash: 0.02 − 0.20 mm (0.0008 − 0.0079 in.) If the backlash is not within the specification, install a thrust washer of different thickness. Z06893 (e) Install the pinion shaft pin and washer. Torque: 27 N·m (275 kgf·cm, 20 ft·lbf) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SA−88 SUSPENSION AND AXLE 2. (a) (b) (c) − REAR DIFFERENTIAL CARRIER w/ DIFFERENTIAL LOCK: MEASURE SIDE GEAR BACKLASH Apply all of the sliding and rotating surfaces with gear oil. Install the thrust washer to the side gear. Install the thrust washer to the pinion gear. SA0510 (d) (e) (f) (g) (h) (i) (j) R08274 (k) Install the side gear into the case. Install the holder into the case. Install the 4 pinion gears with the thrust washers. Align the pinion shaft hole and case pinion shaft pin hole, and install the pinion shaft. Install the side gear to the cover. Align the matchmarks and install the case and cover. Using a torx socket wrench, torque the 5 bolts and 3 pinion shaft pins. Torque: 58 N·m (590 kgf·cm, 43 ft·lbf) Using a dial indicator, with holding the side gear and measure the backlash. Backlash: 0.02 − 0.20 mm (0.0008 − 0.0079 in.) HINT: Measure at all 4 locations. If the backlash is not within the specification, install the thrust washer of a different thickness. Thrust washer thickness R08276 Thickness Thickness mm (in.) 1.60 (0.063) 1.90 (0.075) 1.75 (0.069) 2.05 (0.081) (l) After measuring backlash, remove the 5 set bolts and 3 pinion shaft pins. 3. w/ DIFFERENTIAL LOCK: ASSEMBLE DIFFERENTIAL CASE Clean the thread of the bolts, pinion shaft pins, case and cover with the white gasoline. Coat the threads of the bolts and pinion shaft pins with adhesive. Adhesive: Part No. 08833−00070, THREE BOND 1324 or equivalent Align the matchmarks, install the case and cover. (a) (b) R13246 mm (in.) (c) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SA−89 SUSPENSION AND AXLE REAR DIFFERENTIAL CARRIER (d) Using a torx socket wrench, torque the 5 bolts and 3 pinion shaft pins. Torque: 58 N·m (590 kgf·cm, 43 ft·lbf) 4. (a) INSTALL SIDE BEARINGS w/o Differential lock: Using SST and a press, install the 2 side bearings on the differential case. SST 09315−00022, 09550−10012 (09558−10010) w/ Differential lock: Using SST and a press, install the 2 side bearings on the differential case. SST 09550−60010, 09550−10012 (09558−10010) (b) 5. (a) Boiling Water − (b) (c) (d) INSTALL RING GEAR ON DIFFERENTIAL CASE Clean the contact surfaces of the differential case and ring gear. Heat the ring gear to about 100°C (212°F) in boiling water. Carefully remove the ring gear from the boiling water. After the moisture on the ring gear has completely evaporated, quickly install the ring gear to the differential case. SA1143 (e) Align the matchmarks on the ring gear and differential case. (f) Temporarily install the set bolts and nuts so that the bolt holes in the ring gear and differential case are not misaligned. NOTICE: Install the bolts so that the tapered part of the bolt is on the ring gear side. The ring gear set nuts should not tighten until the ring gear has cooled sufficiently. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SA−90 SUSPENSION AND AXLE After the ring gear cools down enough, tighten the set bolts uniformly and a little at a time. Torque: 110 N·m (1,125 kgf·cm, 81 ft·lbf) 6. (a) CHECK RING GEAR RUNOUT Install the differential case onto the carrier and tighten the adjusting nut just to where there is no play in the bearings. Using a dial indicator, check the ring gear runout. Maximum runout: 0.10 mm (0.0039 in.) Remove the differential case. (c) SST 7. Rear SST (a) (b) SA2425 REAR DIFFERENTIAL CARRIER (g) (b) Front − INSTALL DRIVE PINION FRONT AND REAR BEARING OUTER RACES Front side: Using SST and a press, install the 2 outer races. SST 09950−60020 (09951−00710), 09950−70010 (09951−07150) Rear side: Using SST and a press, install the 2 outer races. SST 09950−60020 (09951−00890), 09950−70010 (09951−07150) INSTALL DRIVE PINION REAR BEARING Install the washer on the drive pinion. SA3102 8. (a) HINT: First fit a washer with the same thickness as the washer which was removed, then after checking the tooth contact pattern, replace the washer with one of a different thickness if necessary. (b) Using SST and a press, install the rear bearing onto the drive pinion. SST 09506−35010 R13414 9. TEMPORARILY ADJUST DRIVE PINION PRELOAD (a) Install the drive pinion and front bearing. HINT: Assemble the spacer and oil seal after adjusting the gear contact pattern. (b) Install the oil slinger. (c) Install the companion flange with SST. SST 09550−30010 (09951−03010, 09953−03010, 09954−03010, 09955−03030, 09956−03020) SST SST 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SA−91 SUSPENSION AND AXLE − REAR DIFFERENTIAL CARRIER (d) Adjust the drive pinion preload by tightening the companion flange nut. Using SST to hold the flange, tighten the nut. SST 09330−00021 NOTICE: Coat the nut and screw of the drive pinion with gear oil. As there is no spacer, tighten a little at a time, being careful not to overtighten. SST SA2450 (e) SA2446 Using a torque wrench, measure the preload. Preload (at starting): New bearing 1.3 − 2.0 N·m (13 − 20 kgf·cm, 11.3 − 17.4 in.·lbf) Reused bearing 0.7 − 1.0 N·m (7 − 10 kgf·cm, 6.1 − 8.7 in.·lbf) HINT: Measure the total preload after first turning the bearing clockwise and counterclockwise several times to make the bearing smooth. 10. w/o DIFFERENTIAL LOCK: INSTALL DIFFERENTIAL CASE IN CARRIER (a) Place the 2 bearing outer races on their respective bearings. Make sure that the left and right outer races are not interchanged. (b) Install the case in the carrier. HINT: Make sure that there is backlash between the ring gear and drive pinion. 11. (a) (b) (c) w/ DIFFERENTIAL LOCK: INSTALL DIFFERENTIAL CASE IN CARRIER Place the 2 bearing outer races on their respective bearings. Make sure that the left and right races are not interchanged. Install the assembled plate washer onto the side bearing. Install the differential case in the carrier. R08261 (d) Make the plate washer and bearing smooth by tapping on the ring gear with a plastic hammer. HINT: If it is difficult to install the differential case into the carrier, replace the plate washer with a thinner one. However, select a plate washer that allows no clearance between it and the carrier. R08262 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SA−92 SUSPENSION AND AXLE 12. (a) (b) − REAR DIFFERENTIAL CARRIER w/ DIFFERENTIAL LOCK: ADJUST RING GEAR BACKLASH Using a dial indicator, with holding the side bearing of the ring gear side and measure the backlash. Backlash (reference): 0.15 mm (0.0059 in.) Select a case cover side plate washer using the backlash as reference. R08263 Side plate washer thickness (c) Select a ring gear side plate washer of a thickness which eliminates any clearance between the plate washer and carrier. (d) (e) (f) Remove the 2 plate washers and differential carrier. Install the plate washer into the lower part of the carrier. Place the plate washer onto the differential case together with the outer race, and install the differential case with the outer race into the carrier. Using a plastic hammer, make the washer and bearing smooth by tapping the ring gear. R08264 (g) R08265 (h) Using a dial indicator, measure the ring gear backlash. Backlash: 0.15 − 0.20 mm (0.0059 − 0.0079 in.) If it is not within the specification, adjust it by either increasing or decreasing the number of washers on both sides by an equal amount. HINT: There should be no clearance between the plate washer and case. Ensure that there is ring gear backlash. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SA−93 SUSPENSION AND AXLE 13. (a) (b) (c) RA0090 REAR DIFFERENTIAL CARRIER w/ DIFFERENTIAL LOCK: ADJUST SIDE BEARING PRELOAD After adjustment with the backlash as reference, remove the ring gear side plate washer. Using a micrometer, measure the thickness of the removed plate washer. Install a new thicker washer of 0.06 − 0.09 mm (0.0024 − 0.0035 in.) than the washer removed. HINT: Select a washer which can be pressed in 2/3 of the way with finger. (d) (e) (f) SST − Using SST, tap in the plate washer. SST 09504−22010 Align the matchmarks on the cap and carrier. Tighten the 4 bearing cap bolts to the specified torque. Torque: 113 N·m (1,150 kgf·cm, 83 ft·lbf) R08269 (g) Using a dial indicator, adjust the ring gear backlash until it is within the specification. Backlash: 0.15 − 0.20 mm (0.0059 − 0.0079 in.) If it is not within the specification, follow the procedure listed below. If backlash is greater than the specification: Replace the cover side washer with a thicker washer. When doing so replace the ring gear side plate washer with one having a thickness equalling the amount the cover side plate washer thickness was decreased. If backlash is less than specification: Replace the cover side washer with a thicker washer. When doing so, replace the ring gear side plate washer with one having a thickness equalling the amount the cover side plate washer thickness was increased. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SA−94 SUSPENSION AND AXLE − REAR DIFFERENTIAL CARRIER 14. w/o DIFFERENTIAL LOCK: INSTALL ADJUSTING NUTS Install the 2 adjusting nuts on the carrier, making sure the nuts are threaded properly. 15. w/o DIFFERENTIAL LOCK: INSTALL BEARING CAPS Align the matchmarks on the cap and carrier. Screw in the 2 bearing cap bolts 2 or 3 turns and press down the bearing cap by hand. HINT: If the bearing cap does not fit tightly on the carrier, the adjusting nuts are not threaded properly. Reinstall the adjusting nuts if necessary. 16. (a) (b) (c) (d) SST w/o DIFFERENTIAL LOCK: ADJUST SIDE BEARING PRELOAD Torque the 4 bearing cap bolts to the specified torque, then loosen them to the point where the adjusting nuts can be turned by SST. SST 09504−00011 Torque:78 N·m (800 kgf·cm, 58 ft·lbf) Fully tighten the 4 bearing cap bolts by hand. Using the SST, torque the adjusting nut on the ring gear side until the ring has a backlash of about 0.2 mm (0.008 in.). With turning the ring gear, use the SST to fully tighten the adjusting nut on the drive pinion side. After the bearings as settled, loosen the adjusting nut on the drive pinion side. Z06953 (e) (f) Place a dial indicator on the top of the adjusting nut on the ring gear side. Adjust the side bearing for zero preload by tightening the other adjusting nut until the pointer on the indicator begins to move. SA2444 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SA−95 SUSPENSION AND AXLE − REAR DIFFERENTIAL CARRIER (g) Using the SST, torque the adjusting nut 1−1.5 notches from the zero preload position. (h) Using a dial indicator, adjust the ring gear backlash until it is within the specification. Backlash: 0.15 − 0.20 mm (0.0059−0.0079 in.) HINT: The backlash is adjusted by turning the left and right adjusting nuts equal amounts. For example, loosen the nut on the left side one notch and torque the nut on the right side one notch. Z06918 (i) Torque the 4 bearing cap bolts. Torque:78 N·m (800 kgf·cm, 58 ft·lbf) (j) Recheck the ring gear backlash. Backlash: 0.15 − 0.20 mm (0.0059−0.0079 in.) 17. MEASURE TOTAL PRELOAD Using a torque wrench, measure the preload. Total preload (at starting): Drive pinion preload plus w/o Differential lock 0.4 − 0.6 N·m (4 − 6 kgf·cm, 3.5 − 5.2 in.·lbf) w/ Differential lock 0.3− 0.7 N·m (3 − 7 kgf·cm, 2.6 − 6.1 in.·lbf) 18. (a) (b) INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION Coat 3 or 4 teeth at 3 different positions on the ring gear with red lead. Turn the companion flange, pin both directions to inspect the ring gear for proper tooth contact. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SA−96 SUSPENSION AND AXLE − REAR DIFFERENTIAL CARRIER Heel Contact Face Contact Proper Contact Select an adjusting washer that will bring the drive pinion closer to the ring gear. Flank Contact Toe Contact Select an adjusting washer that will shift the drive pinion away from the ring gear. FA2013 If the teeth are not contacting properly, use the following chart to select a proper washer for correction. Thickness Washer FA2041 mm (in.) Thickness mm (in.) 1.05 (0.0413) 1.35 (0.0531) 1.10 (0.0433) 1.40 (0.0551) 1.15 (0.0453) 1.45 (0.0571) 1.20 (0.0472) 1.50 (0.0591) 1.25 (0.0492) 1.55 (0.0610) 1.30 (0.0512) − 19. 20. REMOVE COMPANION FLANGE (See page SA−29) REMOVE OIL SLINGER AND FRONT BEARING (See page SA−29) 21. (a) (b) INSTALL BEARING SPACER AND FRONT BEARING Install a new bearing spacer on the shaft. Install the front bearing and oil slinger. SA2394 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SA−97 SUSPENSION AND AXLE 22. (a) (b) SST − REAR DIFFERENTIAL CARRIER INSTALL OIL SEAL Using SST and a hammer, install a new oil seal, as shown. SST 09214−76011 Oil seal drive in depth: 1.0 mm (0.039 in.) Apply MP grease to the oil seal lip. SA2454 23. (a) SST INSTALL COMPANION FLANGE Install the companion flange with SST. SST 09550−30010 (09951−03010, 09953−03010, 09954−03010, 09955−03030, 09956−03020) Install the plate washer and a new nut. (b) HINT: Coat the threads of a new nut with gear oil. R13414 (c) SST Using SST to hold the flange, tighten the nut. SST 09330−00021 Torque: 245 N·m (2,500 kgf·cm, 181 ft·lbf) SA2351 SA2446 24. ADJUST DRIVE PINION PRELOAD Using a torque wrench, measure the preload of the backlash between the drive pinion and ring gear. Preload (at starting): New bearing 1.3 − 2.0 N·m (13 − 20 kgf·cm, 11.3 − 17.4 in.·lbf) Reused bearing 0.7 − 1.0 N·m (7 − 10 kgf·cm, 6.1 − 8.7 in.·lbf) If the preload is greater than the specification, replace the bearing spacer. If the preload is less than the specification, retighten the nut a little at a time 13 N·m (130 kgf·cm, 9 ft·lbf) until the specified preload is reached. Maximum torque: 441 N·m (4,500 kgf·cm, 326 ft·lbf) If the maximum torque is exceeded while retightening the nut, replace the bearing spacer and repeat the preload procedure. Do not back off the pinion nut to reduce the preload. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SA−98 SUSPENSION AND AXLE − REAR DIFFERENTIAL CARRIER 25. RECHECK RING GEAR BACKLASH Using a dial indicator, measure the ring gear backlash. Ring gear backlash: 0.15 − 0.20 mm (0.0059 − 0.0079 in.) 26. RECHECK TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION 27. CHECK RUNOUT OF COMPANION FLANGE (See page SA−80) 28. (a) (b) 29. (a) FIPG Width Approx. 1 − 2 mm (0.04 − 0.08 in.) Z15220 (b) w/o DIFFERENTIAL LOCK: INSTALL ADJUSTING NUT LOCKS Install 2 new nut locks on the bearing caps. Tightening 2 bolts, bend the nut locks. Torque: 13 N·m (130 kgf·cm, 9 ft·lbf) w/ DIFFERENTIAL LOCK: INSTALL ACTUATOR, SHIFT FORK AND SLEEVE Clean contacting surfaces of any FIPG material using gasoline or alcohol. Apply FIPG to the actuator. FIPG: Part No. 08826−00090, THREE BOND 1281 or equivalent HINT: Install the actuator within 10 minutes after applying FIPG. (c) Install the actuator to the differential and match the shift fork hole. (d) Clean the threads of set bolt and fork shaft with the white gasoline. Coat the threads of the set bolt with adhesive. Adhesive: Part No. 08833−00070, THREE BOND 1324 or equivalent Tighten the shift fork shaft set bolt. Torque: 20 N·m (200 kgf·cm, 14 ft·lbf) SA2129 (e) Adhesive (f) Z10150 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SA−99 SUSPENSION AND AXLE − REAR DIFFERENTIAL CARRIER (g) Engage the sleeve with the dog clutch of the differential case. (h) Tighten the 4 bolts. Torque: 24 N·m (240 kgf·cm, 17 ft·lbf) 30. w/ DIFFERENTIAL LOCK: INSTALL COVER Clean contacting surfaces of any FIPG material using gasoline or alcohol. Apply FIPG to the cover. FIPG: Part No. 08826−00090, THREE BOND 1281 or equivalent SA2133 SA2131 (a) (b) FIPG Width Approx. 1 − 2 mm (0.04 − 0.08 in.) Z15219 HINT: Install the cover within 10 minutes after applying FIPG. (c) Tighten the 3 bolts. Torque: 18 N·m (185 kgf·cm, 13 ft·lbf) 31. w/ DIFFERENTIAL LOCK: INSTALL INDICATOR SWITCH Install the indicator switch with a new gasket. Torque: 40 N·m (410 kgf·cm, 30 ft·lbf) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SA−100 SUSPENSION AND AXLE − REAR DIFFERENTIAL CARRIER SA1VK−01 INSTALLATION Installation is in the reverse order of removal (See page SA−79). HINT: After installation, fill the differential with gear oil (See page SA−27). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SA−101 SUSPENSION AND AXLE − DIFFERENTIAL LOCKING SYSTEM DIFFERENTIAL LOCKING SYSTEM ON−VEHICLE INSPECTION SA1VL−03 1. (a) INSPECT DIFFERENTIAL LOCK SYSTEM Inspect the indicator lights. Check that the indicator lights (front side and rear side) light up for approx. 1 second when the ignition switch is turned ON. (b) Inspect the differential lock operation. (1) Jack up the vehicle then start the engine. (2) Put the transfer shift lever on the L position. (3) When the Diff. lock control switch is set to the RR position, the indicator light (rear side) is turned on. Differential lock is applied to the rear wheel at this time. HINT: If the gears of the differential lock system are not meshed, the indicator light remains blinking, so rotate the tires to mesh the gear. (4) When the Diff. lock control switch is at the OFF position, the indicator light goes off. Differential lock is released for the rear wheel at this time. (5) When the Diff. lock control switch is set to the FR/ RR position, the indicator lights (front side and rear side) are turned on. Differential lock is applied to both the front wheels and rear wheels at this time. 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 958 Brought to you by BirfMark SA−102 SUSPENSION AND AXLE M3 M4 − DIFFERENTIAL LOCKING SYSTEM (6) Check the voltage between the terminals of the Diff. lock ECU when switching the Diff. lock control switch with the speedometer, registering approx. 8 km/h (5 mph) or more. (7) Check that the indicator lights blink when center Diff. lock release mode is set. Diff. lock is released for both the front wheels and rear wheels at this time. Return the Diff. lock control switch to OFF. Stop the engine and lower the vehicle. M1 M2 Z07254 (8) (9) 2. (a) Wire Harness Side INSPECT DIFF. LOCK SYSTEM CIRCUIT Inspect the system circuit with connector disconnected. Disconnect the connector from the Diff. lock ECU and inspect the connector on the wire harness side, as shown in the chart. Z07255 Trouble Part/ Terminals (Symbols) Condition Specified Value Rear diff. lock actuator/ 1 (M2) − 3 (M1) − Less than 100 Ω Front diff. lock actuator/ 5 (M4) − 7 (M1) − Less than 100 Ω Body ground/ 13 (GND) − Body ground − Continuity Vehicle speed sensor/ 4(SPD) − Body ground Vehicle moving slowly 1 pulse each 40 cm (15.75 in.) 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 959 Brought to you by BirfMark SA−103 SUSPENSION AND AXLE DIFF. fuse/ 8 (IG) − Body ground Battery positive voltage Ignition switch ON, Indicator light (Rear) ON About 0 V Ignition switch ON, Indicator light (Rear) OFF Battery positive voltage Ignition switch ON, Indicator light (front) ON. About 0 V Ignition switch ON, Indicator light (front) OFF Battery positive voltage Ignition switch ON, Indicator light (Center diff. lock) ON About 0 V Ignition switch ON, Indicator light (Center diff. lock) OFF Battery positive voltage Ignition switch ON, Diff. lock control switch RR or FR RR Battery positive voltage Ignition switch ON, Diff. lock control switch OFF About 0 V Ignition switch ON, Diff. lock control switch FR RR Battery positive voltage Ignition switch ON, Diff. lock control switch OFF or RR About 0 V Front diff. lock position switch/ 9 (FLP) − Body ground Differential lock control switch/ 12 (R) − Body ground Differential lock control switch/ 6 (RF) − Body ground DIFFERENTIAL LOCKING SYSTEM Ignition switch ON Rear diff. lock position switch/ 2 (RLP) − Body ground Center diff. indicator switch/ 15 (4WD) − Body groud − HINT: When a signal enters the ECU to LOCK the front differential and set the rear differential to FREE (when battery positive voltage is inputted to terminal 6 (RF) of ECU and about 0 V is inputted to terminal 12 (R)), or a signal to FREE both the front and rear differentials, the indicator lights keep blinking until the ignition switch is turned off (Fail−safe function). If the circuit is not as specified, check and repair or replace the trouble part shown in the table above. (b) Inspect the battery positive voltage Battery positive voltage: 10 − 14.5 V (c) Inspect the system circuit with connector connected (1) Turn the ignition switch to the ON position. (2) Keep the center Diff. lock condition. (3) Remove the Diff. lock ECU. (4) ECU Side Using a voltmeter, measure the voltage when the differential lock control switch is in the position, as shown below. Terminals (Symbols) Switch Position STD Voltage (V) 15 (4WD) − 13 (GND) − 0.5 or less 9 (FLP) − 13 (GND) FR RR 0.5 or less 2 (RLP) − 13 (GND) RR or FR RR 0.5 or less Z07256 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 960 Brought to you by BirfMark SA−104 SUSPENSION AND AXLE − DIFFERENTIAL LOCKING SYSTEM OFF − RR 0.5 or less → 10 − 14.5 (Approx. 1 sec) → 0.5 or less RR − OFF 0.5 or less → 10 − 14.5 (Approx. 1 sec) → 0.5 or less OFF or RR − FR RR 0.5 or less → 10 − 14.5 (Approx. 1 sec) → 0.5 or less FR RR − RR or OFF 0.5 or less → 10 − 14.5 (Approx. 1 sec) → 0.5 or less 3 (M1) − 1 (M2) 1 (M2) − 3 (M1) 7 (M3) − 5 (M4) 5 (M4) − 7 (M3) If the circuit is not as specified, replace the ECU. (d) Install the ECU in place. Heater Main Relay 2 3. INSPECT DIFF. LOCK ACTUATOR (a) Jack up the vehicle. (b) Use the heater main relay and connect it, as shown below. NOTICE: Connect the terminals being careful not to touch the neighboring terminals or metallic parts of relay housing. (c) Rotate the tire and check that differential lock has occurred. If operation is not as specified, replace the actuator. Relay Housing Metallic Parts 3 1 5 4 W02075 Free−Lock Lock−Free Heater Main Relay Heater Main Relay Battery Battery Z07257 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 961 Brought to you by BirfMark SA−105 SUSPENSION AND AXLE 4 − DIFFERENTIAL LOCKING SYSTEM 4. INSPECT DIFF. LOCK CONTROL SWITCH Inspect the switch continuity between terminals, as shown. 2 1 Switch Position Terminals Specified Condition OFF 1−2 No continuity 1−4 No continuity 1−2 No continuity 1−4 Continuity 1−2 Continuity 1−4 Continuity RR FR RR SA1948 If continuity is not as specified, replace the switch. 5. (a) Ohmmeter Z07264 INSPECT DIFF. LOCK POSITION SWITCH Front and Rear: Inspect the diff. lock position switch. (1) Check that there is continuity between terminals when the switch is pushed (differential connected position). (2) Check that there is no continuity when the switch is free (differential disconnected position). If operation is not as specified, replace the switch. (b) Inspect the center diff. indicator switch. 6. INSPECT VEHICLE SPEED SENSOR AND INDICATOR LIGHT (a) Inspect the vehicle speed sensor (See page BE−34). (b) Inspect the indicator light. 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 962 Brought to you by BirfMark SA−106 SUSPENSION AND AXLE − DIFFERENTIAL LOCKING SYSTEM DIFFERENTIAL LOCKING SYSTEM SA1VM−01 LOCATION 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SA−107 SUSPENSION AND AXLE − DIFFERENTIAL LOCKING SYSTEM REMOVAL SA1VN−02 1. (a) (b) REMOVE FRONT ACTUATOR Shifting the front differential lock. Disconnect the connector and tube. (c) (d) Remove the 2 nuts, bolt and actuator. Remove the O−ring from the actuator. 2. (a) (b) REMOVE REAR ACTUATOR Shifting the gear differential lock. Remove the actuator protector. Remove the 2 nuts, bolt and protector. (c) (d) Disconnect the connectors and tube. Remove the rear Diff. lock position switch. (e) Remove the cover. (1) Remove the 3 bolts. (2) Using a brass bar and hammer, remove the cover. Z07258 Z07261 SA2619 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SA−108 SUSPENSION AND AXLE − DIFFERENTIAL LOCKING SYSTEM (f) Remove the shift fork set bolt. (g) (h) Remove the 4 bolts. Using a screwdriver, pry out the actuator. SA2621 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SA−109 SUSPENSION AND AXLE − DIFFERENTIAL LOCKING SYSTEM INSTALLATION 1. (a) Outside Shift Fork SA1VO−02 INSTALL FRONT ACTUATOR Check that the outermost rack tooth of the shift fork is virtually above the center line of the actuator installation hole. Actuator Installation Hole Z07259 (b) 3 2 1.5 Using a dry cell battery, align the matchmark on the pinion with the center line of the actuator. NOTICE: S If the pinion of the actuator is not in the specified place, the actuator is difficult to be installed. S Do not supply the battery positive voltage between terminals. S If the matchmark comes to the extension limit of the rotation, do not electrify moreover. 50° 108° Matchmark (Groove) R08154 (c) (d) (e) Install a new O−ring to the actuator. Apply a light coat of gear oil on the O−ring. Apply MP grease to the gear part of the actuator. (f) Install the actuator to the differential with the 2 nuts and bolt, so that the outermost rack tooth of the shift fork will fit matchmark of the pinion of the actuator. SA2306 HINT: Do not damage the O−ring of the actuator. Torque: 26 N·m (270 kgf·cm, 20 ft·lbf) SA2420 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SA−110 SUSPENSION AND AXLE − DIFFERENTIAL LOCKING SYSTEM (g) Connect the connector and tube. HINT: S The depth of the insertion of the bleeder tube into the hose is approx. 15 mm (0.59 in.). S Take care that water or the equivalent will not adhere to the connector and hose. (h) Cancel the front differential lock. With the ignition switch ON, turn the differential lock control switch to OFF to cancel the differential lock. 2. (a) FIPG Width Approx. 1 − 2 mm (0.04 − 0.08 in.) (b) INSTALL REAR ACTUATOR Clean contacting surfaces of any FIPG material using gasoline or alcohol. Apply FIPG to the actuator. FIPG: Part No. 08826−00090, THREE BOND 1281 or equivalent HINT: Install the actuator within 10 minutes after applying FIPG. Z15220 (c) (d) (e) Adhesive (f) Z07262 Install the actuator to the differential and match the shaft with the shaft fork hole. Clean the threads of the set bolt and shaft fork with the white gasoline. Coat the threads of the set bolt with adhesive. Adhesive: Part No. 08833−00070, THREE BOND 1324 or equivalent Tighten the shift fork set bolt. Torque: 20 N·m (200 kgf·cm, 14 ft·lbf) (g) Tighten the 4 bolts uniformly, a little at a time. Torque: 24 N·m (240 kgf·cm, 17 ft·lbf) (h) Install the cover. (1) Clean the contacting surfaces of any FIPG material using gasoline or alcohol. (2) Apply FIPG to the cover. FIPG: Part No. 08826−00090, THREE BOND 1281 or equivalent SA2620 HINT: Install the cover within 10 minutes after applying FIPG. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SA−111 SUSPENSION AND AXLE − DIFFERENTIAL LOCKING SYSTEM (3) Tighten the 3 bolts. Torque: 18 N·m (185 kgf·cm, 13 ft·lbf) SA2619 (i) Install the rear Diff. position switch. Install the position switch with a new gasket. Torque: 40 N·m (410 kgf·cm, 30 ft·lbf) (j) Connect the connectors and tube. HINT: S The depth of the insertion of the bleeder tube into the hose is approx. 15 mm (0.59 in.). S Take care that the water or the equivalent will not adhere to the connectors and hose. (k) (l) Install the actuator protector. Install the protector with the 2 nuts and bolt. Torque: Nut: 35 N·m (360 kgf·cm, 26 ft·lbf) Bolt: 20 N·m (200 kgf·cm, 14 ft·lbf) Cancel the rear differential lock. With the ignition switch ON, turn the differential lock control switch to OFF to cancel the differential lock. Z07261 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SA−112 SUSPENSION AND AXLE − COIL SPRING AND REAR SHOCK ABSORBER COIL SPRING AND REAR SHOCK ABSORBER SA1VR−03 COMPONENTS 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 969 Brought to you by BirfMark SA−113 SUSPENSION AND AXLE − COIL SPRING AND REAR SHOCK ABSORBER REMOVAL 1. 2. (a) (b) (c) (d) 3. 4. SA1VP−01 REMOVE REAR WHEEL Torque: Steel wheel: 147 N·m (1,500 kgf·cm, 109 ft·lbf) Aluminum wheel: 103 N·m (1,050 kgf·cm, 76 ft·lbf) REMOVE REAR SHOCK ABSORBER Remove the lower bolt holding the shock absorber from the rear axle housing. Torque: 64 N·m (650 kgf·cm, 47 ft·lbf) Remove the retainer and 2 cushions, disconnect the shock absorber. Remove the 2 upper bolts and shock absorber. Torque: 50 N·m (510 kgf·cm, 37 ft·lbf) Remove these parts from the shock absorber: S Nut S 3 Retainers S 2 Cushions S Bracket Torque: 69 N·m (700 kgf·cm, 51 ft·lbf) DISCONNECT STABILIZER BAR BRACKETS FROM REAR AXLE HOUSING (See page SA−124) DISCONNECT LATERAL CONTROL ROD FROM REAR AXLE HOUSING (See page SA−118) 5. REMOVE COIL SPRING (a) Begin to lower the axle housing. HINT: Be careful not to snap the brake line and parking brake cable. R08418 (b) With lowering the rear axle housing, remove the coil spring and insulator. HINT: Check that the coil spring end is installed correctly. If the coil spring end is not in the correct position, reinstall the coil spring. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SA−114 SUSPENSION AND AXLE (c) − COIL SPRING AND REAR SHOCK ABSORBER Remove the bolt and follow spring from the frame. Torque: 28 N·m (290 kgf·cm, 21 ft·lbf) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SA−115 SUSPENSION AND AXLE − COIL SPRING AND REAR SHOCK ABSORBER INSPECTION SA0627 SA1VQ−01 INSPECT SHOCK ABSORBER Compress and extend the shock absorber rod and check that there is no abnormal resistance or unusual operation sounds. If there is any abnormality, replace the shock absorber with a new one. NOTICE: When discarding the shock absorber, use the following procedure. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SA−116 SUSPENSION AND AXLE − COIL SPRING AND REAR SHOCK ABSORBER DISPOSAL SA1VS−01 DISCARD SHOCK ABSORBER Before discarding the shock absorber, drill a hole 2 − 3 mm (0.079 − 0.118 in.) in diameter at the location shown in the illustration to release the gas inside. NOTICE: When drilling, chips may fly out, work carefully. The gas is colorless, odorless and non−poisonous. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SA−117 SUSPENSION AND AXLE − COIL SPRING AND REAR SHOCK ABSORBER SA1VT−01 INSTALLATION Installation is in the reverse order of removal (See page SA−113). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SA−118 SUSPENSION AND AXLE − REAR LATERAL CONTROL ROD REAR LATERAL CONTROL ROD SA1VU−01 REMOVAL 1. REMOVE REAR WHEEL Torque: Steel wheel: 147 N·m (1,500 kgf·cm, 109 ft·lbf) Aluminum wheel: 103 N·m (1,050 kgf·cm, 76 ft·lbf) 2. (a) REMOVE LATERAL CONTROL ROD Remove the bolt, nut and plate washer, and disconnect the lateral control rod. Torque: 177 N·m (1,800 kgf·cm, 130 ft·lbf) HINT: After stabilizing the suspension, torque the bolt. (b) Remove the bolt and lateral control rod from the axle housing. Torque: 245 N·m (2,500 kgf·cm, 181 ft·lbf) HINT: After stabilizing the suspension, torque the bolt. 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 975 Brought to you by BirfMark SA−119 SUSPENSION AND AXLE − REAR LATERAL CONTROL ROD REPLACEMENT REPLACE LATERAL CONTROL ROD BUSHING (a) Using SST and a press, remove the bushing. SST 09550−10012 (09553−10010), 09710−22021 (09710−01071) SST SST R13240 (b) SST Using SST and a press, install a new bushing. SST 09550−10012 (09553−10010), 09710−22021 (09710−01071) SST R13241 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 SA1VV−01 Brought to you by BirfMark SA−120 SUSPENSION AND AXLE − REAR LATERAL CONTROL ROD SA1VW−01 INSTALLATION Installation is in the reverse order of removal (See page SA−118). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SA−121 SUSPENSION AND AXLE − REAR UPPER AND LOWER CONTROL ARM REAR UPPER AND LOWER CONTROL ARM REMOVAL 1. SA1VX−01 REMOVE REAR WHEEL Torque: Steel wheel: 147 N·m (1,500 kgf·cm, 109 ft·lbf) Aluminum wheel: 103 N·m (1,050 kgf·cm, 76 ft·lbf) 2. REMOVE UPPER CONTROL ARM Remove the 2 bolts, plate washers, nuts and upper control arm from the frame. Torque: 177 N·m (1,800 kgf·cm, 130 ft·lbf) HINT: After stabilizing the suspension, torque the bolt. 3. REMOVE LOWER CONTROL ARM Remove the 2 bolts, plate washers, nuts and lower control arm from the frame. Torque: 177 N·m (1,800 kgf·cm, 130 ft·lbf) HINT: After stabilizing the suspension, torque the bolt. 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 978 Brought to you by BirfMark SA−122 SUSPENSION AND AXLE − REAR UPPER AND LOWER CONTROL ARM REPLACEMENT SST SA1VY−01 1. (a) REPLACE UPPER CONTROL ARM BUSHING Using SST and a press, remove the bushing. SST 09226−10010, 09950−60010 (09951−00490), 09950−70010 (09951−07100) (b) Using SST and a press, install a new bushing. SST 09226−10010, 09506−35010 2. (a) REPLACE LOWER CONTROL ARM BUSHING Using SST and a press, remove the bushing. SST 09506−35010, 09950−60010 (09951−00540), 09950−70010 (09951−07100) (b) Using SST and a press, install a new bushing, as shown. SST 09316−20011, 09506−35010 R13242 SST SST R13243 SST R13244 SST W02078 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SA−123 SUSPENSION AND AXLE − REAR UPPER AND LOWER CONTROL ARM SA1VZ−01 INSTALLATION Installation is in the reverse order of removal (See page SA−121). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SA−124 SUSPENSION AND AXLE − REAR STABILIZER BAR SA1W0−01 REMOVAL REMOVE STABILIZER BAR (a) Loosen the 2 bolts and nuts. Torque: 25 N·m (260 kgf·cm, 19 ft·lbf) HINT: After stabilizing the suspension, torque the nut. (b) Remove the nuts and disconnect the stabilizer bar with the links from the bracket. Torque: 15 N·m (153 kgf·cm, 11 ft·lbf) HINT: After stabilizing the suspension, torque the nut. (c) Remove the 2 bolts, nuts and links from the stabilizer bar. (d) Remove the 4 bolts and stabilizer bar from the axle housing with the covers. Torque: 18 N·m (185 kgf·cm, 13 ft·lbf) HINT: After stabilizing the suspension, torque the bolt. (e) Remove the 2 covers and cushions from the stabilizer bar. HINT: Install the cushions and brackets touching the line painted on the stabilizer bar. 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 981 Brought to you by BirfMark SA−125 SUSPENSION AND AXLE − REAR STABILIZER BAR SA1W1−01 INSTALLATION Installation is in the reverse order of removal (See page SA−124). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SF−1 SFI − SFI SYSTEM SFI SYSTEM SF1ED−04 PRECAUTION 1. BEFORE WORKING ON FUEL SYSTEM, DISCONNECT NEGATIVE (−) TERMINAL CABLE FROM THE BATTERY. HINT: Any diagnostic trouble code retained by the computer will be erased when the negative (−) terminal cable is disconnected. Therefore, if necessary, read the diagnosis before disconnecting the negative (−) terminal cable from the battery. 2. DO NOT SMOKE OR WORK NEAR AN OPEN FLAME WHEN WORKING ON FUEL SYSTEM. 3. KEEP GASOLINE AWAY FROM RUBBER OR LEA THER PARTS 4. MAINTENANCE PRECAUTIONS (a) In event of engine misfire, these precautions should be taken. (1) Check proper connection of battery terminals, etc. (2) Handle high−tension cords carefully. (3) After repair work, check that the ignition coil terminals and all other ignition system lines are reconnected securely. (4) When cleaning the engine compartment, be especially careful to protect the electrical system from water. (b) Precautions when handling the oxygen sensor. (1) Do not allow the oxygen sensor to drop or hit against an object. (2) Do not allow the sensor to come in contact with water. 5. IF VEHICLE IS EQUIPPED WITH MOBILE RADIO SYSTEM (HAM, CB, ETC.) If the vehicle is equipped with a mobile communication system, refer to the precaution in the IN section. 6. AIR INDUCTION SYSTEM (a) Separation of the engine oil dipstick, oil filler cap, PCV hose, etc. may cause the engine to run out of tune. (b) Disconnection, looseness or cracks in the parts of the air induction system between the throttle body and cylinder head will allow air suction and cause the engine to run out of tune. 7. ELECTRONIC CONTROL SYSTEM (a) Before removing SFI wiring connectors, terminals, etc., first disconnect the power by either turning the ignition switch OFF or disconnecting the negative (−) terminal cable from the battery. 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 629 Brought to you by BirfMark SF−2 SFI − SFI SYSTEM HINT: Always check the diagnostic trouble code before disconnecting the negative (−) terminal cable from the battery. (b) When installing the battery, be especially careful not to incorrectly connect the positive (+) and negative (−) cables. (c) Do not permit parts to receive a severe impact during removal or installation. Handle all SFI parts carefully, especially the ECM. (d) Do not be careless during troubleshooting as there are numerous transistor circuits and even slight terminal contact can further troubles. (e) Do not open the ECM cover. (f) (g) (h) Lock Press Down P03244 (i) Insert Lock P03245 (j) When inspecting during rainy weather, take care to prevent entry of water. Also, when washing the engine compartment, prevent water from getting on the SFI parts and wiring connectors. Parts should be replaced as an assembly. Care is required when pulling out and inserting wiring connectors. (1) Release the lock and pull out the connector, pulling on the connectors. (2) Fully insert the connector and check that it is locked. When inspecting a connector with a volt/ohmmeter (1) Carefully take out the water−proofing rubber if it is a water−proof type connector. (2) Insert the test probe into the connector from the wiring side when checking the continuity, amperage or voltage. (3) Do not apply unnecessary force to the terminal. (4) After checking, install the water−proofing rubber on the connector securely. Use SST for inspection or test of the injector or its wiring connector. SST 09842−30070 SST FI2553 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 630 Brought to you by BirfMark SF−3 SFI 8. (a) − FUEL SYSTEM When disconnecting the high fuel pressure line, a large amount of gasoline will spill out, so observe the following procedures: (1) Disconnect the fuel pump connector. (2) Start the engine. After the engine has stopped on its own, turn off the ignition switch. (3) (4) (5) (6) (7) (b) Fulcrum Length 30 cm SST FI1654 SFI SYSTEM Put a container under the connection. Slowly loosen the connection. Disconnect the connection. Plug the connection with 2 rubber plugs. Reconnect the fuel pump connector. When connecting the union bolt on the high pressure pipe union, observe the following procedures: (1) Always use a new gasket. (2) Tighten the union bolt by hand. (3) Tighten the union bolt to the specified torque. Torque: 29 N·m (300 kgf·cm, 21 ft·lbf) (c) When connecting the flare nut on the high pressure pipe union, observe the following procedures: (1) Apply a light coat of engine oil to the flare and tighten the flare nut by hand. (2) Using SST, tighten the flare nut to the specified torque. SST 09631−22020 NOTICE: Do not rotate the fuel pipe, when tightening the flare nut. Torque: 30 N·m (310 kgf·cm, 22 ft·lbf) HINT: Use a torque wrench with a fulcrum length of 30 cm (11.81 in.). 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 631 Brought to you by BirfMark SF−4 SFI New O−ring Grommet CORRECT − SFI SYSTEM (d) Observe the following precautions when removing and installing the injectors. (1) Never reuse the O−ring. (2) When placing a new O−ring on the injector, take care not to damage it in any way. (3) Coat a new O−ring with spindle oil or gasoline before installing−never use engine, gear or brake oil. (e) Install the injector to the delivery pipe and intake manifold as shown in the illustration. Injector WRONG Delivery Pipe P09286 (f) Check that there are no fuel leaks after doing maintenance anywhere on the fuel system. (1) Remove the fuse cover on the instrument panel. (2) Connect the TOYOTA hand−held tester to the DLC3. (3) Turn the ignition switch ON and TOYOTA hand− held tester main switch ON. NOTICE: Do not start the engine. (4) Select the active test mode on the TOYOTA hand− held tester. (5) Please refer to the TOYOTA hand−held tester operator’s manual for further details. If you have no TOYOTA hand−held tester, connect the positive (+) and negative (−) leads from the battery to the fuel pump connector (See page SF−14). (6) Fuel Return Hose P09401 Pinch the fuel return hose. The pressure in the high pressure line will rise to approx. 392 kPa (4 kgf/cm2, 57 psi). In this state, check to see that there are no leaks from any part of the fuel system. NOTICE: Always pinch the hose. Avoid bending as it may cause the hose to crack. (7) Turn the ignition switch to LOCK. (8) Disconnect the TOYOTA hand−held tester from the DLC3. 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 632 Brought to you by BirfMark SF−5 SFI (g) − SFI SYSTEM Install the fuse cover on the instrument panel. 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 633 Brought to you by BirfMark SF−9 SFI − FUEL PUMP SF1EF−01 COMPONENTS 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SF−10 SFI − FUEL PUMP 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SF−11 SFI − FUEL PUMP REMOVAL SF1EH−02 CAUTION: Do not smoke or work near an open flame when working on the fuel pump. 1. REMOVE SECOND SEATS Torque: 39 N·m (400 kgf·cm, 29 ft·lbf) 2. REMOVE SCUFF PLATE 3. REMOVE SIDE GARNISH 4. REMOVE STEP PLATE 5. DISCONNECT FLOOR MATS 6. REMOVE FLOOR SERVICE HOLE COVER Remove the 3 screws and service hole cover. 7. DISCONNECT FUEL PIPE AND HOSE FROM FUEL PUMP BRACKET CAUTION: Remove the fuel filter cap to prevent the fuel from flowing out. (a) Disconnect the fuel pump and sender gauge connector. HINT: At the time of installation, plaese refer to the following items. Check for fuel leakage. (b) (c) Remove the union bolt and gaskets, and disconnect the outlet pipe from the pump bracket. Torque: 29 N·m (300 kgf·cm, 22 ft·lbf) Disconnect the return hose from the pump bracket. 8. REMOVE FUEL PUMP BRACKET ASSEMBLY FROM FUEL TANK (a) Remove the 8 bolts. Torque: 3.9 N·m (40 kgf·cm, 35 in.·lbf) (b) Pull out the pump bracket assembly. NOTICE: S Do not damage the fuel pump filter. S Be careful that the arm of the sender gauge should not bent. (c) Remove the gasket from the pump bracket. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SF−12 SFI − FUEL PUMP HINT: At the time of installation, plaese refer to the following items. install a new gasket to the pump bracket. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SF−13 SFI − FUEL PUMP DISASSEMBLY 1. (a) (b) (c) (d) SF1EI−03 REMOVE FUEL PUMP FROM FUEL PUMP BRACKET Pull off the lower side of the fuel pump from the pump bracket. Disconnect the fuel pump connector. Disconnect the fuel hose from the fuel pump, and remove the fuel pump. Remove the rubber cushion from the fuel pump. 2. REMOVE FUEL PUMP FILTER FROM FUEL PUMP (a) Using a small screwdriver, remove the clip. HINT: At the time of installation, plaese refer to the following items. install the pump filter with a new clip. (b) Pull out the pump filter. 3. (a) (b) REMOVE FUEL SENDER GAUGE FROM FUEL PUMP BRACKET Remove the 3 screws and disconnect the lead wires from the pump bracket. Remove the 2 screws and sender gauge. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SF−14 SFI − FUEL PUMP INSPECTION 1. 2. 3. 4. 5. SF1EG−02 REMOVE SECOND SEATS REMOVE SCUFF PLATE REMOVE SIDE GARNISH REMOVE STEP PLATE DISCONNECT FLOOR MATS 6. REMOVE FLOOR SERVICE HOLE COVER Remove the 3 screws and service hole cover. 7. DISCONNECT FUEL PUMP AND SENDER GAUGE CONNECTOR 8. INSPECT FUEL PUMP RESISTANCE Using an ohmmeter, measure the resistance between the terminals 5 and 6. Resistance: 0.2 − 3.0 Ω at 20°C (68°F) If the resistance is not as specified, replace the fuel pump. 9. INSPECT FUEL PUMP OPERATION Connect the positive (+) lead from the battery to terminal 6 of the connector, and the negative (−) lead to terminal 5. Check that the fuel pump operates. NOTICE: S These tests must be performed quickly (within 10 seconds) to prevent the coil from burning out. S Keep the fuel pump as far away from the battery as possible. S Always perform switching at the battery side. If operation is not as specified, replace the fuel pump. 10. RECONNECT FUEL PUMP AND SENDER GAUGE CONNECTOR 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SF−15 SFI − FUEL PUMP 11. REINSTALL FLOOR SERVICE HOLE COVER Install the service hole cover with the 3 screws. 12. REINSTALL FLOOR MATS 13. REINSTALL STEP PLATE 14. REINSTALL SIDE GARNISH 15. REINSTALL SCUFF PLATE 16. REINSTALL SECOND SEATS Torque: 39 N·m (400 kgf·cm, 29 ft·lbf) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SF−16 SFI − FUEL PUMP SF1EJ−01 REASSEMBLY Reassembly is in the reverse order of disassembly (See page SF−13). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SF−17 SFI − FUEL PUMP SF1EK−01 INSTALLATION Installation is in the reverse order of removal (See page SF−11). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SF−18 SFI − FUEL FILTER FUEL FILTER SF1EL−01 COMPONENTS 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 646 Brought to you by BirfMark SF−19 SFI − FUEL PRESSURE REGULATOR FUEL PRESSURE REGULATOR SF1EM−01 ON−VEHICLE INSPECTION INSPECT FUEL PRESSURE (See page SF−1) 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 647 Brought to you by BirfMark SF−20 SFI − FUEL PRESSURE REGULATOR SF0XZ−04 COMPONENTS 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SF−21 SFI − FUEL PRESSURE REGULATOR REMOVAL SF0Y0−06 1. DISCONNECT VACUUM SENSING HOSE FROM FUEL PRESSURE REGULATOR 2. DISCONNECT FUEL RETURN HOSE FROM FUEL PRESSURE REGULATOR CAUTION: Put a shop towel under the pressure regulator. 3. (a) (b) REMOVE FUEL PRESSURE REGULATOR Loosen the lock nut, and remove the pressure regulator. Remove the O−ring from the pressure regulator. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SF−22 SFI − FUEL PRESSURE REGULATOR INSTALLATION 1. (a) (b) (c) (d) (e) 2. 3. 4. SF0Y1−06 INSTALL FUEL PRESSURE REGULATOR Fully loosen the lock nut on the pressure regulator. Apply a light coat of gasoline to a new O−ring, and install it to the pressure regulator. Insert the pressure regulator into the delivery pipe by hand completely. Turn the pressure regulator counterclockwise until the fuel outlet port faces in the direction indicated in the illustration. Tighten the lock nut. Torque: 25 N·m (250 kgf·cm, 18 ft·lbf) CONNECT FUEL RETURN HOSE TO FUEL PRESSURE REGULATOR CONNECT VACUUM SENSING HOSE TO FUEL PRESSURE REGULATOR START ENGINE AND CHECK FOR FUEL LEAKAGE 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SF−22 SFI − FUEL PRESSURE REGULATOR INSTALLATION 1. (a) (b) (c) (d) (e) 2. 3. 4. SF0Y1−06 INSTALL FUEL PRESSURE REGULATOR Fully loosen the lock nut on the pressure regulator. Apply a light coat of gasoline to a new O−ring, and install it to the pressure regulator. Insert the pressure regulator into the delivery pipe by hand completely. Turn the pressure regulator counterclockwise until the fuel outlet port faces in the direction indicated in the illustration. Tighten the lock nut. Torque: 25 N·m (250 kgf·cm, 18 ft·lbf) CONNECT FUEL RETURN HOSE TO FUEL PRESSURE REGULATOR CONNECT VACUUM SENSING HOSE TO FUEL PRESSURE REGULATOR START ENGINE AND CHECK FOR FUEL LEAKAGE 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SF−23 SFI − INJECTOR INJECTOR ON−VEHICLE INSPECTION SF0OR−05 1. 2. (a) (b) REMOVE THROTTLE BODY (See page SF−45) INSPECT INJECTOR RESISTANCE Disconnect the 6 injector connectors. Using an ohmmeter, measure the resistance between the terminals. Resistance: 13.4 − 14.2 Ω at 20°C (68°F) If the resistance is not as specified, replace the injector. (c) Reconnect the 6 injector connectors. 3. REINSTALL THROTTLE BODY (See page SF−48) 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 651 Brought to you by BirfMark SF−24 SFI − INJECTOR SF0OS−05 COMPONENTS 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SF−25 SFI − INJECTOR 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SF−26 SFI − INJECTOR SF1EN−01 REMOVAL 1. 2. 3. 4. 5. 6. 7. DRAIN ENGINE COOLANT DISCONNECT CRUISE CONTROL ACTUATOR CABLE DISCONNECT ACCELERATOR CABLE DISCONNECT THROTTLE CABLE DISCONNECT NO.2 PCV HOSE DISCONNECT AIR CLEANER HOSE REMOVE EGR VACUUM MODULATOR AND VALVE (See page EC−10) 8. REMOVE BOLT HOLDING HEATER INLET PIPE AND AIR INTAKE CHAMBER 9. 10. 11. 12. 13. DISCONNECT DISCONNECT DISCONNECT DISCONNECT DISCONNECT 14. DISCONNECT THROTTLE POSITION SENSOR CONNECTOR DISCONNECT IDLE AIR CONTROL VALVE CONNECTOR DISCONNECT CONNECTOR FOR EMISSION CONTROL VALVE SET ASSEMBLY DISCONNECT EGR GAS TEMP. SENSOR CONNECTOR 15. 16. 17. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 NO.1 PCV HOSE VACUUM SENSING HOSE NO.2 WATER BYPASS HOSE EVAP HOSE BRAKE BOOSTER HOSE Brought to you by BirfMark SF−27 SFI − INJECTOR 18. DISCONNECT PS RESERVOIR TANK Remove the 3 bolts and disconnect the reservoir tank. 19. REMOVE ENGINE OIL DIPSTICK 20. DISCONNECT GROUND STRAP 21. REMOVE INTAKE MANIFOLD STAY Remove the 2 bolts and intake manifold stay. 22. 23. DISCONNECT VACUUM HOSES FROM TVV DISCONNECT NO.1 WATER BYPASS HOSE FROM CYLINDER HEAD 24. REMOVE AIR INTAKE CHAMBER Remove the 6 bolts, 2 nuts, air intake chamber and 2 gaskets. 25. (a) (b) REMOVE FUEL RETURN PIPE Disconnect the fuel hose from the fuel pressure regulator. Remove the 2 bolts and fuel return pipe. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SF−28 SFI − INJECTOR 26. REMOVE FUEL INLET PIPE Remove the 2 union bolts, bolt, 4 gaskets and fuel pipe. 27. (a) (b) REMOVE DELIVERY PIPE AND INJECTORS Disconnect the 6 injector connectors. Remove the 3 bolts and delivery pipe together with the 6 injectors. NOTICE: Be careful not to drop the injectors when removing the delivery pipe. (c) Remove the 6 insulators and 3 spacers from the intake manifold. (d) Pull out the 6 injectors from the delivery pipe. (e) Remove the O−ring and grommet from each injector. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SF−29 SFI − INJECTOR INSPECTION SF1EO−03 1. INSPECT INJECTOR INJECTION CAUTION: Keep injector clean of sparks during the test. (a) Connect SST (union and hose) to the fuel filter outlet with the 2 gaskets and union bolt. SST 09268−41046 (90405−09015) Torque: 29 N·m (300 kgf·cm, 22 ft·lbf) (b) (c) (d) Remove the fuel pressure regulator (See page SF−21). Install the O−ring to the fuel inlet of pressure regulator. Connect SST (hose) to the fuel inlet of the pressure regulator with SST (union). SST 09268−41046 (09268−41091) Torque: 25 N·m (250 kgf·cm, 18 ft·lbf) Connect the fuel return hose to the fuel outlet of the pressure regulator. (e) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SF−30 SFI (f) (g) − INJECTOR Install the grommet and O−ring to the injector. Connect SST (union and hose) to the injector, and hold the injector and union with SST (clamp). SST 09268−41046 Put the injector into the graduated cylinder. (h) HINT: Install a suitable vinyl hose onto the injector to prevent gasoline from splashing out. (i) Remove the fuse cover on the instrument panel. (j) (k) Connect the TOYOTA hand−held tester to the DLC3. Turn the ignition switch ON and TOYOTA hand−held tester main switch ON. NOTICE: Do not start the engine. (l) Select the active test mode on the TOYOTA hand−held tester. (m) Please refer to the TOYOTA hand−held tester operator’s manual for further details. (n) (o) FI4848 FI4849 If you have no TOYOTA hand−held tester, connect the positive (+) and negative (−) leads from the battery to the fuel pump connector (See page SF−14) Connect SST (wire) to the injector and battery for 15 seconds, and measure the injection volume with a graduated cylinder. Test each injector 2 or 3 times. SST 09842−30070 Volume: 69 − 88 cm3 (4.2 − 5.4 cu in.) per 15 seconds Difference between each injector: 5 cm3 (0.3 cu in.) or less If the injection volume is not as specified, replace the injector. 2. INSPECT LEAKAGE (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) Turn the ignition switch to LOCK. (c) Disconnect the negative (−) terminal cable from the battery. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SF−31 SFI (d) (e) (f) (g) − INJECTOR Remove SST. SST 09268−41045 Reinstall the fuel pressure regulator to the delivery pipe (See page SF−22). Disconnect the TOYOTA hand−held tester from the DLC3. Reinstall the fuse cover on the instrument panel. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SF−32 SFI − INJECTOR INSTALLATION SF1EP−01 1. (a) (b) INSTALL INJECTORS AND DELIVERY PIPE Install a new grommet to the injector. Apply a light coat of gasoline to a new O−ring and install it to the injector. (c) While turning the injector left and right, install it to the delivery pipe. Install the 6 injectors. Position the injector connector upward. FI6429 (d) (e) (f) (g) Place 6 new insulators and the 3 spacers in position on the intake manifold. Place the 6 injectors together with the delivery pipe in position on the intake manifold. Temporarily install the 3 bolts holding the delivery pipe to the intake manifold. (h) Check that the injectors rotate smoothly. HINT: If injectors do not rotate smoothly, the probable cause is incorrect installation of O−rings. Replace the O−rings. (i) Position the injector connector upward. (j) Tighten the 3 bolts holding the delivery pipe to the intake manifold. Torque: 21 N·m (210 kgf·cm, 15 ft·lbf) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SF−33 SFI (k) − INJECTOR Connect the 6 injector connectors as shown. 2. INSTALL FUEL INLET PIPE Install the fuel inlet pipe with 4 new gaskets, the 2 union bolts and bolt. Torque: Union bolt: 29 N·m (300 kgf·cm, 22 ft·lbf) Bolt: 20 N·m (200 kgf·cm, 14 ft·lbf) 3. (a) (b) INSTALL FUEL RETURN PIPE Install the fuel return pipe with the 2 bolts. Torque: 20 N·m (200 kgf·cm, 14 ft·lbf) Connect the fuel hose to the fuel pressure regulator. 4. INSTALL AIR INTAKE CHAMBER Install 2 new gaskets and the air intake chamber with the 6 bolts and 2 nuts. Torque: 21 N·m (210 kgf·cm, 15 ft·lbf) 5. 6. CONNECT NO.1 WATER BYPASS HOSE TO CYLINDER HEAD CONNECT VACUUM HOSES TO TVV 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SF−34 SFI − INJECTOR 7. INSTALL INTAKE MANIFOLD STAY Install the intake manifold stay with the 2 bolts. Torque: 36 N·m (360 kgf·cm, 26 ft·lbf) 8. CONNECT GROUND STRAP 9. INSTALL ENGINE OIL DIPSTICK 10. CONNECT PS RESERVOIR TANK Connect the reservoir tank with the 3 bolts. Torque: 18 N·m (185 kgf·cm, 13 ft·lbf) 11. 12. 13. 14. CONNECT EGR GAS TEMP. SENSOR CONNECTOR CONNECT CONNECTOR FOR EMISSION CONTROL VALVE SET ASSEMBLY CONNECT IDLE AIR CONTROL VALVE CONNECTOR CONNECT THROTTLE POSITION SENSOR CONNECTOR 15. 16. 17. 18. 19. CONNECT BRAKE BOOSTER HOSE CONNECT EVAP HOSE CONNECT NO.2 WATER BYPASS HOSE CONNECT VACUUM SENSING HOSE CONNECT NO.1 PCV HOSE 20. INSTALL BOLT HOLDING HEATER INLET PIPE AND AIR INTAKE CHAMBER Torque: 20 N·m (200 kgf·cm, 14 ft·lbf) INSTALL EGR VALVE AND VACUUM MODULATOR (See page EC−10) CONNECT THROTTLE CABLE CONNECT ACCELERATOR CABLE CONNECT CRUISE CONTROL ACTUATOR CABLE CONNECT AIR CLEANER HOSE CONNECT NO.2 PCV HOSE 21. 22. 23. 24. 25. 26. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SF−35 SFI 27. − INJECTOR FILL WITH ENGINE COOLANT 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SF−36 SFI − FUEL TANK AND LINE FUEL TANK AND LINE SF0OZ−12 COMPONENTS CAUTION: S Always use new gaskets when replacing the fuel tank or component parts. S Apply the proper torque to all parts tightened. 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 664 Brought to you by BirfMark SF−37 SFI − FUEL TANK AND LINE INSPECTION BO0919 SF0P0−06 INSPECT FUEL TANK AND LINE (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 illustration. If a problem is found, repair or replace the part as necessary. Z00085 FU0041 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SF−38 SFI − MASS AIR FLOW (MAF) METER MASS AIR FLOW (MAF) METER SF0P1−06 COMPONENTS 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 666 Brought to you by BirfMark SF−39 SFI − MASS AIR FLOW (MAF) METER REMOVAL 1. (a) (b) (c) (d) SF1ER−01 REMOVE AIR CLEANER CAP AND MAF METER Disconnect the MAF meter connector and wire clamp. Disconnect the cruise control actuator cable. Loosen the air cleaner hose clamp. Disconnect the 3 clips, and remove the wing nut, air cleaner cap and MAF meter. P22902 2. REMOVE MAF METER Remove the 4 bolts, bracket and MAF meter. Torque: 6.9 N·m (70 kgf·cm, 61 in.·lbf) P22624 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SF−40 SFI − MASS AIR FLOW (MAF) METER SF1ES−01 INSPECTION 1. INSPECT MAF METER RESISTANCE Using an ohmmeter, measure the resistance between terminals THA and E2. FI6961 Between terminals Resistance Temperature THA − E2 10 − 20 kΩ −20°C (−4°F) THA − E2 4 − 7 kΩ 0°C (32°F) THA − E2 2 − 3 kΩ 20°C (68°F) THA − E2 0.9 − 1.3 kΩ 40°C (104°F) THA − E2 0.4 − 0.7 kΩ 60°C (140°F) THA − E2 0.2 − 0.4 kΩ 80°C (176°F) If the resistance is not as specified, replace the MAF meter. 2. (a) (b) INSPECT MAF METER OPERATION Connect the MAF meter connector. Using a voltmeter, connect the positive (+) tester probe to terminal VG, and negative (−) tester probe to terminal E3. (c) Blow air into the MAF meter, and check that the voltage fluctuates. If operation is not as specified, replace the MAF meter. (d) Disconnect the MAF meter connector. Z11824 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SF−41 SFI − MASS AIR FLOW (MAF) METER SF1ET−01 INSTALLATION Installation is in the reverse order of removal (See page SF−39). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SF−42 SFI − THROTTLE BODY THROTTLE BODY SF1EU−01 ON−VEHICLE INSPECTION 1. (a) INSPECT THROTTLE BODY Check that the throttle linkage moves smoothly. (b) Check the vacuum at each port. S Start the engine. S Check the vacuum with your finger. 2. (a) (b) (c) (d) 3. (a) (b) (c) (d) Port name At idle At 3,500 rpm P No vacuum Vacuum E No vacuum Vacuum R No vacuum Vacuum INSPECT THROTTLE POSITION (TP) SENSOR Disconnect the TP sensor connector. Apply vacuum to the throttle opener. Using an ohmmeter, measure the resistance between each terminal. Throttle valve condition Between terminals Fully closed VTA − E2 0.2 − 5.7 kΩ Fully closed IDL − E2 2.3 kΩ or less Open IDL − E2 Infinity Fully open VTA − E2 2.0 − 10.2 kΩ − VC − E2 2.5 − 5.9 kΩ Resistance Reconnect the TP sensor connector. INSPECT AND ADJUST DASHPOT Allow the engine to warm up to normal operating temperature. Check the idle speed. Idle speed: 650 ± 50 rpm (N position) Open the throttle valve until the throttle lever separates from the dashpot end. Release the throttle valve gradually, and check the dashpot setting speed when the throttle lever touched the dashpot end. Dashpot setting speed: 2,200 ± 300 rpm 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 670 Brought to you by BirfMark SF−43 SFI − THROTTLE BODY If not as specified, adjust using the following procedure: (1) Stop the engine. (2) Loosen the lock nut of the stopper bolt. (3) Adjust the dashpot setting speed by turning the stopper bolt. (4) Start the engine and check the dashpot setting speed. (5) Retighten the lock nut. (e) Maintain the engine at 3,500 rpm. (f) Release the throttle valve, and check that the engine returns to idle in a few seconds. 4. (a) CHECK THROTTLE OPENER Disconnect the vacuum hose from the throttle opener, and plug the hose end. (b) Check the throttle opener setting speed. Throttle opener setting speed: 700 − 1,000 rpm If the throttle opener setting is not as specified, replace the throttle body. (c) Stop the engine. (d) Reconnect the vacuum hose to the throttle opener. (e) Start the engine, and check that the idle speed returns to the correct speed. Idle speed: 650 ± 50 rpm (N position) 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 671 Brought to you by BirfMark SF−44 SFI − THROTTLE BODY SF1EV−01 COMPONENTS 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SF−45 SFI − THROTTLE BODY REMOVAL 1. 2. 3. 4. 5. 6. SF1EW−04 DRAIN ENGINE COOLANT DISCONNECT NO.2 PCV HOSE DISCONNECT AIR CLEANER HOSE DISCONNECT CONTROL CABLES FROM THROTTLE BODY DISCONNECT THROTTLE POSITION SENSOR CONNECTOR DISCONNECT IDLE AIR CONTROL VALVE CONNECTOR 7. (a) (b) (c) REMOVE THROTTLE BODY Disconnect the EVAP hose. Disconnect the 3 vacuum hoses. Disconnect the No.2 water bypass hose. (d) Remove the 4 bolts, and disconnect the throttle body from the air intake chamber. Torque: 21 N·m (210 kgf·cm, 15 ft·lbf) Remove the throttle body gasket. (e) HINT: At the time of installation, plaese refer to the following items. install a new gasket on the air intake chamber. (f) (g) Disconnect the No.1 water bypass hose from the throttle body, and remove the throttle body. Disconnect the No.2 water bypass hose from the throttle body. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SF−46 SFI − THROTTLE BODY SF1EX−01 INSPECTION 1. (a) CLEAN THROTTLE BODY Using a soft brush and carburetor cleaner, clean the cast parts. (b) Using compressed air, clean all the passages and apertures. NOTICE: To prevent deterioration, do not clean the throttle position sensor, dashpot and IAC valve. 2. (a) (b) INSPECT THROTTLE VALVE Apply vacuum to the throttle opener. Check that there is no clearance between the throttle stop screw and throttle lever when the throttle valve is fully closed. 3. (a) (b) INSPECT THROTTLE POSITION SENSOR Apply vacuum to the throttle opener. Insert a 0.50 mm (0.020 in.) or 0.75 mm (0.030 in.) feeler gauge between the throttle stop screw and stop lever. Using an ohmmeter, measure the resistance between each terminal. (c) 4. (a) Clearance between lever and stop screw Between terminals Resistance 0 mm (0 in.) VTA − E2 0.2 − 5.7 kΩ 0.50 mm (0.020 in.) IDL − E2 2.3 kΩ or less 0.75 mm (0.030 in.) IDL − E2 Infinity Throttle valve fully open VTA − E2 2.0 − 10.2 kΩ − VC − E2 2.5 − 5.9 kΩ IF NECESSARY, ADJUST THROTTLE POSITION SENSOR Loosen the 2 set screws of the sensor. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SF−47 SFI (b) (c) (d) − THROTTLE BODY Apply vacuum to the throttle opener. Insert a 0.62 mm (0.024 in.) feeler gauge between the throttle stop screw and stop lever. Connect the test probe of an ohmmeter to the terminals IDL and E2 of the sensor. (e) Gradually turn the sensor clockwise until the ohmmeter deflects, and secure it with the 2 set screws. (f) Recheck the continuity between terminals IDL and E2. Clearance between lever and stop screw Continuity (IDL − E2) 0.50 mm (0.020 in.) Continuity 0.75 mm (0.030 in.) No continuity 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SF−48 SFI − THROTTLE BODY SF1EY−01 INSTALLATION Installation is in the reverse order of removal (See page SF−45). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SF−49 SFI − IDLE AIR CONTROL (IAC) VALVE IDLE AIR CONTROL (IAC) VALVE ON−VEHICLE INSPECTION SF1EZ−01 1. INSPECT IAC VALVE FOR OPERATING SOUND Check that there is a clicking sound immediately after stopping the engine. If the operation is not as specified, check the IAC valve, wiring and ECM. 2. (a) (b) INSPECT IAC VALVE RESISTANCE Disconnect the IAC valve connector. Using an ohmmeter, measure the resistance between the terminals (B1−S1 and S3, B2−S2 and S4). Resistance: At Cold: −10 − 50°C (−50 − 122°F): 15 − 25 Ω At Hot: 50 −100°C (122 − 212°F): 20 − 30 Ω If resistance is not as specified, replace the IAC valve. (c) Reconnect the IAC valve connector. 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 677 Brought to you by BirfMark SF−50 SFI − IDLE AIR CONTROL (IAC) VALVE SF1F0−01 COMPONENTS 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SF−51 SFI − IDLE AIR CONTROL (IAC) VALVE REMOVAL SF1F1−01 1. REMOVE THROTTLE BODY (See page SF−45) 2. REMOVE IAC VALVE Remove the 2 screws, IAC valve and O−ring. HINT: At the time of installation, install the IAC valve with a new O− ring. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SF−52 SFI − IDLE AIR CONTROL (IAC) VALVE INSPECTION SF1F2−01 INSPECT IDLE AIR CONTROL VALVE OPERATION (a) Apply battery voltage to terminals B1 and B2, and while repeatedly grounding S1−S2−S3−S4−S1 in sequence, and check that the valve moves toward the closed position. (b) Apply battery voltage to terminals B1 and B2, and while repeatedly grounding S4−S3−S2−S1−S4 in sequence, and check that the valve moves toward the open position. If operation is not as specified, replace the IAC valve. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SF−53 SFI − IDLE AIR CONTROL (IAC) VALVE SF1F3−01 INSTALLATION Installation is in the reverse order of removal (See page SF−51). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SF−54 SFI − EFI MAIN RELAY EFI MAIN RELAY SF06G−11 INSPECTION 1. REMOVE EFI MAIN RELAY LOCATION: In the engine compartment relay box. Ohmmeter Ohmmeter Continuity No Continuity 2 1 4 3 3. (a) (b) INSPECT EFI MAIN RELAY OPERATION Apply battery voltage across terminals 1 and 3. Using an ohmmeter, check that there is continuity between terminals 2 and 4. If operation is not as specified, replace the relay. 4. REINSTALL EFI MAIN RELAY Continuity 4 INSPECT EFI MAIN RELAY CONTINUITY 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. P05668 Ohmmeter 2 2. (a) 1 3 Battery P05667 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 682 Brought to you by BirfMark SF−55 SFI − CIRCUIT OPENING RELAY CIRCUIT OPENING RELAY SF1F4−01 COMPONENTS Circuit Opening Relay Foot Rest Scuff Plate P22674 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 683 Brought to you by BirfMark SF−56 SFI Ohmmeter 2 Continuity 1 4 3 4 SF1F5−01 1. 2. (a) REMOVE CIRCUIT OPENING RELAY INSPECT CIRCUIT OPENING RELAY CONTINUITY 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. P05668 3. (a) (b) INSPECT CIRCUIT OPENING RELAY OPERATION Apply battery voltage across terminals 1 and 3. Using an ohmmeter, check that there is continuity between terminals 2 and 4. If operation is not as specified, replace the relay. 4. REINSTALL CIRCUIT OPENING RELAY Ohmmeter 2 CIRCUIT OPENING RELAY INSPECTION Ohmmeter No Continuity − 1 3 Battery P05667 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SF−57 SFI − FUEL PUMP RELAY FUEL PUMP RELAY SF1F7−01 INSPECTION 1. (a) (b) Ohmmeter Continuity FP PR Ohmmeter +B2 Ohmmeter 2. (a) INSPECT FUEL PUMP RELAY CONTINUITY Using an ohmmeter, check that there is continuity between terminals +B1 and FPR. (b) Check that there is continuity between terminals +B2 and FP. (c) Check that there is no continuity between terminals +B2 and PR. If continuity is not as specified, replace the relay. Ohmmeter Continuity FPR +B1 No Continuity P09134 3. (a) (b) INSPECT FUEL PUMP RELAY OPERATION Apply battery voltage across terminals +B1 and FPR. Using an ohmmeter, check that there is no continuity between the +B2 and FP. (c) Check that there is continuity between terminals +B2 and PR. If operation is not as specified, replace the relay. 4. REINSTALL FUEL PUMP RELAY No Continuity Ohmmeter +B2 FP PR Continuity REMOVE FUEL PUMP RELAY Disconnect the fuel pump relay connector. Remove the bolt and fuel pump relay. Battery FPR +B1 P09135 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 685 Brought to you by BirfMark SF−58 SFI − FUEL PUMP RESISTOR FUEL PUMP RESISTOR INSPECTION 1. (a) (b) SF1F8−01 REMOVE FUEL PUMP RESISTOR Disconnect the fuel pump resistor connector. Remove the bolt and fuel pump resistor. 2. INSPECT FUEL PUMP RESISTOR Using an ohmmeter, measure the resistance between the terminals. Resistance: 0.70 − 0.76 Ω at 20°C (68°F) If there is no continuity, replace the resistor. 3. REINSTALL FUEL PUMP RESISTOR Torque: 18 N·m (185 kgf·cm, 13 ft·lbf) 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 686 Brought to you by BirfMark SF−59 SFI − VSV FOR FUEL PRESSURE CONTROL VSV FOR FUEL PRESSURE CONTROL INSPECTION 1. 2. SF1F9−01 REMOVE AIR INTAKE CHAMBER (See page EM−28) DISCONNECT VACUUM HOSES AND CONNECTOR 3. INSPECT VSV FOR OPEN CIRCUIT Using an ohmmeter, check that there is continuity between the terminals. Resistance: 37 − 44 Ω at 20°C (68°F) If there is no continuity, replace the VSV. 4. INSPECT VSV FOR GROUND Using an ohmmeter, check that there is no continuity between each terminal and the body. If there is continuity, replace the VSV. 5. (a) INSPECT VSV OPERATION Check that the air flows from pipe E to pipe G. (b) Apply battery voltage across the terminals. (c) Check that the air does not flows from pipe E to the filter. If operation is not as specified, replace the VSV. 6. RECONNECT VACUUM HOSES AND CONNECTOR 7. REINSTALL AIR INTAKE CHAMBER (See page EM−54) 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 687 Brought to you by BirfMark SF−60 SFI − VSV FOR EXHAUST GAS RECIRCULATION (EGR) VSV FOR EXHAUST GAS RECIRCULATION (EGR) SF1F6−01 INSPECTION (See page EC−11) 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 688 Brought to you by BirfMark SF−61 SFI − ENGINE COOLANT TEMPERATURE (ECT) SENSOR ENGINE COOLANT TEMPERATURE (ECT) SENSOR INSPECTION 1. 2. (a) (b) DRAIN ENGINE COOLANT REMOVE ECT SENSOR Disconnect the ECT sensor connector. Using a 19 mm deep socket wrench, remove the ECT sensor and gasket. 3. INSPECT ECT SENSOR Using an ohmmeter, measure the resistance between the terminals. Resistance: Refer to the chart graph If the resistance is not as specified, replace the ECT sensor. 4. REINSTALL ECT SENSOR (a) Using a 19 mm deep socket wrench, install the ECT sensor and gasket. Torque: 24.5 N·m (250 kgf·cm, 17.5 ft·lbf) (b) Connect the ECT sensor connector. 5. REFILL ENGINE COOLANT Ohmmeter RESISTANCE kΩ SF0PO−09 Acceptable TEMPERATURE °C (°F) Z02917 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 689 Brought to you by BirfMark SF−62 SFI − KNOCK SENSOR KNOCK SENSOR SF1FB−01 INSPECTION 1. (a) (b) REMOVE KNOCK SENSOR Disconnect the knock sensor connector. Using SST, remove the knock sensor. SST 09816−30010 2. INSPECT KNOCK SENSOR Using an ohmmeter, check that there is no continuity between the terminal and body. If there is continuity, replace the sensor. Ohmmeter P01630 3. (a) (b) REINSTALL KNOCK SENSOR Using SST, install the knock sensor. SST 09816−30010 Torque: 44 N·m (450 kgf·cm, 33 ft·lbf) Connect the knock sensor connector. 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 690 Brought to you by BirfMark SFI − EXHAUST GAS RECIRCULATION (EGR) GAS TEMPERATURE SENSOR SF−63 EXHAUST GAS RECIRCULATION (EGR) GAS TEMPERATURE SENSOR SF1FA−01 INSPECTION 1. REMOVE EGR GAS TEMPERATURE SENSOR 2. INSPECT EGR GAS TEMPERATURE SENSOR Using an ohmmeter, measure the resistance between the terminals. Ohmmeter Oil FI6320 Temperature Resistance 50°C (122°F) 64 − 97 kΩ 100°C (212°F) 11 − 16 kΩ 150°C (302°F) 2 − 4 kΩ If the resistance is not as specified, replace the sensor. 3. REINSTALL EGR GAS TEMPERATURE SENSOR Torque: 20 N·m (200 kgf·cm, 14 ft·lbf) 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 691 Brought to you by BirfMark SF−64 SFI − HEATED OXYGEN SENSOR HEATED OXYGEN SENSOR INSPECTION SF1FC−01 INSPECT HEATER RESISTANCE OF HEATED OXYGEN SENSORS (a) Disconnect the heated oxygen sensor connector. (b) Using an ohmmeter, measure the resistance between terminals +B and HT. Resistance: 11 − 16 Ω at 20°C (68°F) If resistance is not as specified, replace the heated oxygen sensor. (c) Reconnect the heated oxygen sensor connector. 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 692 Brought to you by BirfMark SF−65 SFI − ENGINE CONTROL MODULE (ECM) ENGINE CONTROL MODULE (ECM) SF0Q0−07 COMPONENTS 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 693 Brought to you by BirfMark SF−66 SFI − ENGINE CONTROL MODULE (ECM) SF0Q1−07 INSPECTION 1. 2. 3. REMOVE ECM INSPECT ECM (See page DI−17) REINSTALL ECM 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SF−67 SFI − FUEL CUT RPM FUEL CUT RPM SF0Q2−08 INSPECTION 1. WARM UP ENGINE Allow the engine to warm up to normal operating temperature. 2. (a) (b) (c) 3. (a) (b) (c) CONNECT TOYOTA HAND−HELD TESTER OR OBD II SCAN TOOL Remove the fuse cover on the instrument panel. Connect the TOYOTA hand−held tester or OBD II scan tool to the DLC3. Please refer to the TOYOTA hand−held tester or OBD II scan tool operator’s manual for further details. INSPECT FUEL CUTOFF PRM Increase the engine speed to at least 3,500 rpm. Use a sound scope to check for injector operating noise. Check that when the throttle lever is released, injector operation noise stops momentarily and then resumes. HINT: Measure with the A/C OFF. Fuel return rpm: 1,200 rpm 4. DISCONNECT TOYOTA HAND−HELD TESTER OR OBD II SCAN TOOL 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 695 Brought to you by BirfMark SR−1 STEERING − STEERING SYSTEM STEERING SYSTEM SR164−01 PRECAUTION S S Care must be taken to replace parts properly because they could affect the performance of the steering system and result in a driving hazard. The LAND CRUISER is equipped with SRS (Supplemental Restraint System) such as the driver airbag and front passenger airbag. Failure to carry out service operation in the correct sequence could cause the SRS to unexpectedly deploy during servicing, possibly leading to a serious accident. Before servicing (including removal or installation of parts, inspection or replacement), be sure to read the precautionary notices in the RS section. 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 1052 Brought to you by BirfMark SR−2 STEERING − TROUBLESHOOTING TROUBLESHOOTING SR165−01 PROBLEM SYMPTOMS TABLE Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely cause of the problem. Check each part in the order shown. If necessary, repair or replace these parts. Symptom Suspect Area See page Hard steering 11.Tires (Improperly inflated) 12.Power steering fluid level (Low) 13.Front wheel alignment (Incorrect) 14.Steering system joints (Worn) 15.Suspension arm ball joints (Worn) 16.Steering column (Binding) 17.Power steering vane pump 18.Power steering gear SA−3 SR−4 SA−4 − − − SR−21 SR−33 Poor return 1. 2. 3. 4. Tires (Improperly inflated) Front wheel alignment (Incorrect) Steering column (Binding) Power steering gear SA−3 SA−4 − SR−33 Excessive play 1. 2. 3. 4. 5. Steering system joints (Worn) Suspension arm ball joints (Worn) Intermediate shaft, Universal joint, Sliding yoke (Worn) Front wheel bearing (Worn) Power steering gear − − − SR−7 SR−33 Abnormal noise 1. 2. 3. 4. Power steering fluid level (Low) Steering system joints (Worn) Power steering vane pump Power steering gear SR−4 − SR−21 SR−33 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 1053 Brought to you by BirfMark SR−3 STEERING − POWER STEERING FLUID POWER STEERING FLUID BLEEDING SR167−01 1. 2. CHECK FLUID LEVEL (See page SR−4) JACK UP FRONT OF VEHICLE AND SUPPORT IT WITH STANDS 3. TURN STEERING WHEEL With the engine stopped, turn the wheel slowly from lock to lock several times. 4. LOWER VEHICLE 5. START ENGINE Run the engine at idle for a few minutes. 6. TURN STEERING WHEEL (a) With the engine idling, turn the wheel to left or right full lock and keep it there for 2−3 seconds, then turn the wheel to the opposite full lock and keep it there for 2−3 seconds. (b) Repeat (a) several times. 7. STOP ENGINE Normal 8. CHECK FOR FOAMING OR EMULSIFICATION If the system has to be bled twice specifically because of foaming or emulsification, check for fluid leaks in the system. 9. CHECK FLUID LEVEL (See page SR−4) Abnormal R07281 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 1054 Brought to you by BirfMark SR−4 STEERING − POWER STEERING FLUID INSPECTION 1. (a) (b) SR166−01 CHECK FLUID LEVEL Keep the vehicle level. With the engine stopped, check the fluid level in the oil reservoir. If necessary, add fluid. Fluid: ATF DEXRON® II or III HINT: Check that the fluid level is within the HOT LEVEL range on the reservoir cap dipstick. If the fluid is cold, check that it is within the COLD LEVEL range. (c) Start the engine and run it at idle. (d) Turn the steering wheel from lock to lock several times to boost fluid temperature. Fluid temperature: 80°C (176°F) Normal (e) Check for foaming or emulsification. If there is foaming or emulsification, bleed power steering system. (See page SR−3). Abnormal R07281 (f) With the engine idling, measure the fluid level in the oil reservoir. (g) Stop the engine. (h) Wait a few minutes and remeasure the fluid level in the oil reservoir. Maximum fluid level rise: 5 mm (0.20 in.) If a problem is found, bleed power steering system (See page SR−3). (i) Check the fluid level. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SR−5 STEERING − POWER STEERING FLUID 2. (a) CHECK STEERING FLUID PRESSURE Disconnect the pressure feed tube from the PS vane pump (See page SR−23). (b) Connect SST over 2 new gaskets, as shown below. SST 09640−10010 (09641−01010, 09641−01030, 09641−01060) NOTICE: Check that the valve of the SST is in the open position. (c) (d) (e) Bleed the power steering system (See page SR−3). Start the engine and run it at idle. Turn the steering wheel from lock to lock several times to boost fluid temperature. Fluid temperature: 80°C (176°F) (f) Oil Reservoir PS Gear Closed SST PS Vane Pump With the engine idling, close the valve of the SST and observe the reading on the SST. Minimum fluid pressure: 9,316kPa (95 kgf/cm2, 1,351 psi) NOTICE: S Do not keep the valve closed for more than 10 seconds. S Do not let the fluid temperature become too high. Z15498 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SR−6 STEERING Oil Reservoir PS Gear Open PS Vane Pump SST − POWER STEERING FLUID (g) (h) With the engine idling, open the valve fully. Measure the fluid pressure at engine speeds of 1,000 rpm and 3,000 rpm. Difference fluid pressure: 490 kPa (5 kgf/cm2, 71 psi) or less NOTICE: Do not turn the steering wheel. Z15499 (i) Lock Position PS Gear Oil Reservoir Open PS Vane Pump SST Z15500 With the engine idling and valve fully opened, turn the steering wheel to full lock. Minimum fluid pressure: 9,316 kPa (95 kgf/cm2, 1,351 psi) NOTICE: S Do not maintain lock position for more than 10 seconds. S Do not let the fluid temperature become too high. (j) Disconnect the SST. (k) Connect the pressure feed tube (See page SR−32). (l) Bleed the power steering system (See page SR−3). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SR−9 STEERING − TILT STEERING COLUMN TILT STEERING COLUMN SR169−01 COMPONENTS 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 1060 Brought to you by BirfMark SR−10 STEERING − TILT STEERING COLUMN 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 1061 Brought to you by BirfMark SR−11 STEERING − TILT STEERING COLUMN REMOVAL SR16A−03 1. REMOVE STEERING WHEEL PAD NOTICE: If the airbag connector is disconnected with the ignition switch at ON or ACC, DTCs will be recorded. Never use airbag parts from another vehicle. When replacing parts, replace with new parts. (a) (b) Place the front wheels facing straight ahead. Remove the steering wheel lower No.2 and No.3 cover from the steering wheel. Using a torx socket wrench, loosen the 2 torx screws. (c) HINT: Loosen the 2 screws until the groove along the screw circumference catches on the screw case. (d) Pull out the wheel pad from the steering wheel and disconnect the airbag connector. CAUTION: When storing the wheel pad, keep the upper surface of the pad facing upward. Never disassemble the wheel pad. NOTICE: When removing the wheel pad, take care not to pull the airbag wire harness. 2. (a) (b) (c) (d) REMOVE STEERING WHEEL Disconnect the connector. Remove the steering wheel set nut. Place matchmarks on the steering wheel and main shaft assembly. Using SST, remove the wheel. SST 09950−50010 (09951−05010, 09952−05010, 09953−05020, 09954−05020) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SR−12 STEERING − TILT STEERING COLUMN 3. (a) REMOVE INSTRUMENT LOWER FINISH PANEL Disconnect the hood lock control cable and fuel lid control cable. (b) Remove the 4 panel set screws. 4. REMOVE NO.2 HEATER TO REGISTER DUCT 5. REMOVE UPPER AND LOWER COLUMN COVERS Remove the 5 screws. 6. REMOVE COMBINATION SWITCH WITH SPIRAL CABLE (a) Disconnect the 2 connectors. (b) Disconnect the airbag connector. (c) Remove the 4 screws. NOTICE: Do not disassemble the cable or apply oil to it. 7. REMOVE 4 COLUMN HOLE COVER SET BOLTS 8. REMOVE LINK JOINT PROTECTOR Remove the 2 bolts. 9. (a) DISCONNECT SLIDING YOKE SUB−ASSEMBLY Place matchmarks on the yoke sub−assembly and worm gear valve body shaft. (b) Loosen bolt A and remove bolt B. 10. REMOVE SLIDING YOKE SUB−ASSEMBLY Remove the bolt A. 11. REMOVE TILT STEERING COLUMN ASSEMBLY (a) Disconnect the 3 connectors. (b) Remove the 2 column assembly set nuts and 2 set bolts. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SR−13 STEERING − TILT STEERING COLUMN DISASSEMBLY SR16B−02 NOTICE: When using a vise, do not overtighten it. 1. DISCONNECT UNIVERSAL JOINT (a) Place matchmarks on the universal joint, intermediate No.2 shaft and main shaft. (b) Remove the 2 bolts. 2. REMOVE LOWER DUST SEAL, COLUMN HOLE COVER AND COLUMN HOLE SHIELD (a) Remove the 2 bolts from the dust seal. (b) Remove the hole shield from the hole cover. 3. REMOVE WIRING HARNESS CLAMP Remove the bolt. 4. (a) (b) (c) 5. (a) (b) 6. 7. (a) (b) 8. (a) (b) (c) (d) 9. REMOVE COLUMN UPPER BRACKET AND COLUMN UPPER CLAMP Using a punch, mark the center of the 2 tapered−head bolts. Using a 3 − 4 mm (0.12 − 0.16 in.) drill, drill into the 2 bolts. Using a screw extractor, remove the 2 bolts. REMOVE COMPRESSION SPRING Remove the bolt. Remove the 2 bushings from the spring. REMOVE 3 TENSION SPRINGS REMOVE 2 TILT LEVER RETAINERS AND TILT PAWL STOPPERS Remove the E−ring from the tilt lever lock shaft. Remove the nut from the tilt No.2 bolt. REMOVE 2 TILT PAWLS Remove the nut and 2 washers from the bolt. Pull out the bolt. Remove the tilt lever assembly set bolt. Remove the collar from the tilt pawl. REMOVE TILT LEVER, TILT SUB LEVER, TILT LEVER ASSEMBLY AND TILT LEVER LOCK SHAFT 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SR−14 STEERING − TILT STEERING COLUMN 10. REMOVE COLUMN UPPER TUBE WITH MAIN SHAFT ASSEMBLY (a) Set SST, the nut (10 mm nominal diameter, 1.25 mm pitch), plate washer (36 mm outer diameter) and bolt (10 mm nominal diameter, 1.25 mm pitch, 50 mm length), as shown. SST 09910−00015 (09911−00011, 09912−00010) Reference Nut: 90170−10004 Plate washer: 90201−10201 Bolt: 91111−51050 (b) Remove the 2 tilt No.2 bolts by using the sliding hammer on SST. (c) Remove the upper tube with the shaft assembly from the column lower tube. 11. REMOVE TURN SIGNAL BRACKET Remove the 2 bolts. 12. (a) SST SST R09496 REMOVE MAIN SHAFT ASSEMBLY Using SST, compress the compression spring. SST 09950−40010 (09957−04010, 09958−04010) NOTICE: Do not bend the sliding yoke of the main shaft assembly more than 20°. (b) Using snap ring pliers, remove the snap ring. (c) Remove the shaft assembly from the column upper tube. (d) Remove the compression spring, bearing thrust collar and bearing from the shaft assembly. 13. REMOVE COLLAR Remove the snap ring and collar from the column lower tube. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SR−15 STEERING − TILT STEERING COLUMN INSPECTION SR16C−01 1. INSPECT STEERING LOCK OPERATION Check that the steering lock mechanism operates properly. 2. (a) (b) IF NECESSARY, REPLACE KEY CYLINDER Place the ignition key at the ACC position. Push down the stop pin with a screwdriver, and pull out the cylinder. Install a new cylinder. (c) HINT: Make sure the key is at the ACC position. 3. INSPECT IGNITION SWITCH (See page BE−11) 4. INSPECT KEY UNLOCK WARNING SWITCH (See page BE−11) 5. IF NECESSARY, REPLACE IGNITION SWITCH WITH KEY UNLOCK WARNING SWITCH (a) Remove the 2 screws. (b) Install a new switches with the 2 screws. 6. INSPECT KEY INTERLOCK SOLENOID (See page SR−9) 7. IF NECESSARY, REPLACE KEY INTERLOCK SOLENOID (a) Remove the 2 screws. (b) Remove the solenoid, spring and lock pin. (c) Install a new solenoid with the spring and lock pin, with the 2 screws. 8. (a) (b) (c) IF NECESSARY, REPLACE BUSHING Using a screwdriver, remove the bushing from the column lower tube. Coat a new bushing with molybdenum disulfide lithium base grease. Align the holes of the tube and projections of the bushing. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SR−16 STEERING − TILT STEERING COLUMN REASSEMBLY SR16D−02 NOTICE: When using a vise, do not overtighten it. 1. COAT WITH MOLYBDENUM DISULFIDE LITHIUM BASE GREASE (See page SR−9) 2. INSTALL MAIN SHAFT ASSEMBLY (a) Install a new bearing, bearing thrust collar and compression spring to the shaft assembly. (b) (c) SST R09496 Install the shaft assembly into the column upper tube. Using SST, compress the compression spring. SST 09950−40010 (09957−04010, 09958−04010) NOTICE: Do not bend the universal joint of the main shaft more than 20°. (d) Using snap ring pliers, install a new snap ring. 3. INSTALL TURN SIGNAL BRACKET Torque the 2 bolts. Torque: 4.9 N·m (50 kgf·cm, 43 in.·lbf) 4. SELECT TILT NO.2 BOLTS Select the bolt with plain thread end when the column upper tube mark is 2, and the bolt with the hollow−tipped thread end when the mark is 1. NOTICE: Select the bolt type to match each number marked in the squares on the upper tube. 5. (a) (b) (c) (d) 6. INSTALL COLUMN UPPER TUBE WITH MAIN SHAFT ASSEMBLY Install the collar to the shaft assembly. Install a new snap ring. Install the upper tube with the shaft assembly into the column lower tube. Using a plastic hammer, drive in the 2 tilt No.2 bolts. INSTALL TILT LEVER LOCK SHAFT, TILT LEVER ASSEMBLY, TILT SUB LEVER AND TILT LEVER 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SR−17 STEERING 7. (a) − TILT STEERING COLUMN INSTALL 2 TILT PAWLS Coat the collar with molybdenum disulfide lithium base grease and install it to the tilt pawl. Install the pawl. (b) HINT: Install the pawl pin into the long hole of the tilt lever/ tilt sub lever. (c) Install the bolt through the pawls and tilt lever assembly. (d) Temporarily install the 2 washers and nut. (e) Torque the tilt lever assembly set bolt. Torque: 2.9 N·m (30 kgf·cm, 26 in.·lbf) 8. ENGAGE AND ADJUST 2 TILT PAWLS (a) Engage the tilt sub lever side pawl to the center of the ratchet. (b) While turning the tilt lever side tilt pawl collar, completely engage the tilt lever side pawl to the ratchet. (c) Torque the nut. Torque: 5.9 N·m (60 kgf·cm, 52 in.·lbf) 9. SELECT AND INSTALL 2 TILT PAWL STOPPERS (a) With the tilt pawl and ratchet engaged, install the stopper. ”A” ”A” (b) Check that the alignment marks on the stopper and pawl align when the stopper is rotated to the pawl side. (c) If the alignment marks do not align, select stopper according to the following table. Mark SR3128 (d) 10. (a) (b) Tilt lever side Tilt sub lever side Dimension ”A” mm (in.) 1 A 12.65 − 12.75 (0.4980 − 0.5020) 2 B 12.55 − 12.65 (0.4941 − 0.4980) 3 C 12.45 − 12.55 (0.4902 − 0.4941) 4 D 12.35 − 12.45 (0.4862 − 0.4902) 5 E 12.25 − 12.35 (0.4823 − 0.4862) After selecting the stoppers, check that on both sides the pawl and ratchet are fully engaged. INSTALL 2 TILT LEVER RETAINERS Install a new E−ring. Torque the nut. Torque: 15 N·m (150 kgf·cm, 11 ft·lbf) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SR−18 STEERING 11. 12. (a) (b) − TILT STEERING COLUMN INSTALL 3 TENSION SPRINGS INSTALL COMPRESSION SPRING Install the 2 bushings to the spring. Torque the bolt. Torque: 7.8 N·m (80 kgf·cm, 69 in.·lbf) 13. INSTALL COLUMN UPPER BRACKET AND COLUMN UPPER CLAMP Tighten 2 new tapered−head bolts until the bolt head brakes off. 14. INSTALL WIRING HARNESS CLAMP Tighten the bolt. 15. INSTALL COLUMN HOLE SHIELD, COLUMN HOLE COVER AND LOWER DUST SEAL (a) Install the hole shield to the hole cover. (b) Install the dust seal to the hole cover. (c) Torque 2 bolts. Torque: 5.9 N·m (60 kgf·cm, 52 in.·lbf) 16. (a) (b) 17. (a) (b) (c) CONNECT UNIVERSAL JOINT Align the matchmarks on the intermediate No.2 shaft and universal joint then torque the bolt. Torque: 34 N·m (350 kgf·cm, 25 ft·lbf) Align the matchmarks on the universal joint and the main shaft then torque the bolt. Torque: 34 N·m (350 kgf·cm, 25 ft·lbf) CHECK TILT STEERING COLUMN OPERATION Check that there is no axial play at the end of the main shaft. With the main shaft in the neutral position, raise the tilt lever and check that the main shaft rises to the uppermost position. Lower the main shaft, and check that it locks in the lowermost position. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SR−19 STEERING − TILT STEERING COLUMN INSTALLATION SR16E−03 1. (a) INSTALL STEERING COLUMN ASSEMBLY Torque the 2 column assembly set nuts and 2 set bolts. Torque:25 N·m (250 kgf·cm, 18 ft·lbf) (b) Connect the 3 connectors. 2. INSTALL SLIDING YOKE SUB−ASSEMBLY Temporarily tighten the bolt A. 3. (a) CONNECT SLIDING YOKE SUB−ASSEMBLY Align the matchmarks on the yoke sub−assembly and worm gear valve body shaft. (b) Torque the bolt B. Torque: 34 N·m (350 kgf·cm, 25 ft·lbf) (c) Torque the bolt A. Torque: 34 N·m (350 kgf·cm, 25 ft·lbf) 4. INSTALL LINK JOINT PROTECTOR Torque the 2 bolts. Torque: 12 N·m (120 kgf·cm, 9 ft·lbf) 5. TORQUE 4 COLUMN HOLE COVER SET BOLTS Torque: 13 N·m (130 kgf·cm, 9 ft·lbf) 6. INSTALL COMBINATION SWITCH WITH SPIRAL CABLE (a) Tighten the 4 screws. (b) Connect the airbag connector. (c) Connect the 2 connectors. 7. INSTALL UPPER AND LOWER COLUMN COVERS Tighten the 5 screws. 8. INSTALL NO.2 HEATER TO REGISTER DUCT 9. INSTALL INSTRUMENT LOWER FINISH PANEL (a) Tighten the 4 panel set screws. (b) Connect the hood lock control cable and fuel lid control cable. 10. (a) (b) (c) CENTER SPIRAL CABLE Check that the front wheels are facing straight ahead. Turn the cable counterclockwise by hand until it becomes harder to turn the cable. Then rotate the cable clockwise about 3 turns to align the red mark. HINT: The cable will rotate about 3 turns to either left or right of the center. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SR−20 STEERING − TILT STEERING COLUMN 11. (a) INSTALL STEERING WHEEL Align the matchmarks on the wheel and main shaft assembly. (b) Torque the wheel set nut. Torque: 34 N·m (350 kgf·cm, 25 ft·lbf) (c) Connect the connector. 12. INSTALL STEERING WHEEL PAD NOTICE: Make sure the wheel pad is installed to the specified torque. If the wheel pad has been dropped, or there are cracks, dents or other defects in the case or connector, replace the wheel pad with a new one. When installing the wheel pad, take care that the wirings do not interfere with other parts and are not pinched between other parts. (a) Connect the airbag connector. (b) Install the wheel pad after confirming that the circumference groove of the torx screws is caught on the screw case. (c) (d) 13. Using a torx socket wrench, torque the 2 screws. Torque: 9.0 N·m (90 kgf·cm, 78 in.·lbf) Install the steering wheel lower No.2 and No.3 cover. CHECK STEERING WHEEL CENTER POINT 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SR−21 STEERING − POWER STEERING VANE PUMP POWER STEERING VANE PUMP SR16F−01 COMPONENTS 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 1072 Brought to you by BirfMark SR−22 STEERING − POWER STEERING VANE PUMP 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 1073 Brought to you by BirfMark SR−23 STEERING − POWER STEERING VANE PUMP REMOVAL SR16G−01 1. DISCONNECT RETURN HOSE 2. DISCONNECT PRESSURE FEED TUBE Remove the union bolt and 2 gaskets. 3. (a) (b) REMOVE PS VANE PUMP ASSEMBLY Remove the 2 nuts. Remove the O−ring from the vane pump assembly. R13336 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SR−24 STEERING − POWER STEERING VANE PUMP DISASSEMBLY R08084 Soft Jaws SR16H−01 NOTICE: When using a vise, do not overtighten it. 1. MEASURE POWER STEERING VANE PUMP ROTATING TORQUE (a) Check that the pump rotates smoothly without abnormal noise. (b) Using a torque wrench, check the pump rotating torque. Rotation torque: 0.3 N·m (2.8 kgf·cm, 2.4 in.·lbf) or less 2. REMOVE SUCTION PORT UNION (a) Remove the bolt. (b) Remove the O−ring from the union. 3. REMOVE VANE PUMP DRIVE GEAR (a) Using soft jaws on a vise, clamp the gear in the vise. NOTICE: Be careful not to damage the gear. (b) Remove the gear set nut. R08066 SST (c) Press SST R13187 Screwdriver Using SST, press out the gear. SST 09527−10011 NOTICE: Be careful not to damage the gear. To avoid dropping the PS pump assembly, support the pump assembly with your hand. (d) Remove the woodruff key from the vane pump shaft. 4. REMOVE PRESSURE PORT UNION, FLOW CONTROL VALVE AND SPRING Remove the O−ring from the union. 5. REMOVE REAR HOUSING AND WAVE WASHER (a) Using 2 screwdrivers, remove the snap ring. NOTICE: Take care not to damage the housing. R08067 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SR−25 STEERING (b) Rear Housing Brass Bar − POWER STEERING VANE PUMP Using a brass bar and hammer, tap the housing so that the spring force of the wave washer pushes the housing forward. R11234 (c) Rear Housing Wood Block R11235 Gently tap the PS pump assembly on a wood block and remove the housing and washer. (d) Remove the O−ring from the housing. 6. REMOVE SIDE REAR PLATE (a) Gently tap the PS pump assembly on a wood block and remove the plate. (b) Remove the O−ring from the plate. 7. REMOVE CAM RING, VANE PUMP ROTOR AND 10 VANE PLATES NOTICE: Be careful not to scratch the cam ring, rotor or vane plates. 8. REMOVE SHORTER STRAIGHT PIN Remove the pin from the side front plate. 9. (a) REMOVE VANE PUMP SHAFT WITH BEARING Using snap ring pliers, remove the snap ring. (b) Using an extension bar and hammer, tap out the shaft with the bearing. R08075 Extension Bar R08074 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SR−26 STEERING − POWER STEERING VANE PUMP 10. (a) REMOVE SIDE FRONT PLATE Using SST, tap out the plate from the front housing. SST 09631−10030 NOTICE: Be careful not to damage the front housing. (b) Remove the 2 O−rings from the plate. 11. REMOVE LONGER STRAIGHT PIN Using pliers, remove the pin from the front housing. SST Side Front Plate R11233 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SR−27 STEERING Vane Pump Shaft POWER STEERING VANE PUMP INSPECTION Caliper Gauge Micrometer − SR16I−02 1. CHECK OIL CLEARANCE BETWEEN VANE PUMP SHAFT AND BUSHING Using a micrometer and caliper gauge, measure the oil clearance. Standard clearance: 0.03 − 0.05 mm (0.0012 − 0.0020 in.) Maximum clearance: 0.07 mm (0.0028 in.) If it is more than maximum, replace the front housing and vane pump shaft. Bushing Front Housing R15644 Thickness 2. (a) INSPECT VANE PUMP ROTOR AND 10 VANE PLATES Using a micrometer, measure the height, thickness and length of the plate. Minimum height: 8.6 mm (0.339 in.) Minimum thickness: 1.397 mm (0.0550 in.) Minimum length: 14.991 mm (0.5902 in.) (b) Using a feeler gauge, measure the clearance between the rotor groove and plate. Maximum clearance: 0.033 mm (0.0013 in.) Height Length N00372 Feeler Gauge R10282 If more than maximum, replace the plate and/or rotor with one having the mark equivalent to the mark stamped on the cam ring. Inscribed mark Vane pump rotor: 1, 2, or None Cam ring: 2, 3, or 4 Inscribed Mark R15645 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SR−28 STEERING − POWER STEERING VANE PUMP HINT: There are 3 vane plate lengths for the following rotor and cam ring marks. Rotor mark None Cam ring mark Vane plate part number 2 44345−60030 1 3 44345−60040 2 4 44345−60050 Vane plate length mm (in.) 14.995 − 14.997 (0.59035 − 0.59043) 14.993 − 14.995 (0.59027 − 0.59035) 14.991 − 14.993 (0.59020 − 0.59027) V08067 3. (a) INSPECT FLOW CONTROL VALVE Coat the valve with power steering fluid and check that it falls smoothly into the valve hole by its own weight. (b) Check the valve for leakage. Close one of the holes and apply 392 − 490 kPa (4 − 5 kgf/cm2, 57 − 71 psi) of compressed air into the opposite side, and confirm that air does not come out from the end holes. Inscribed mark: A, B, C, D, E or F R08078 Compressed Air SR3776 4. INSPECT SPRING Using calipers, measure the free length of the spring. Minimum free length: 35 − 37 mm (1.38 − 1.46 in.) If it is not within the specification, replace the spring. R08702 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SR−29 STEERING − POWER STEERING VANE PUMP 5. (a) IF NECESSARY, REPLACE BEARING Using 2 screwdrivers, remove the snap ring from the vane pump shaft. NOTICE: To prevent vane pump shaft damage, wind tape on the shaft. Tape Screwdriver SR4528 (b) Using a press, press out the bearing. (c) Coat a new bearing with power steering fluid. (d) Using a press, press in the bearing. NOTICE: Be careful not to damage the shaft. (e) Install a new snap ring to the shaft. Press Bearing INSTALL REMOVE R13761 Press Oil Seal SST 6. (a) IF NECESSARY, REPLACE OIL SEAL Using a screwdriver and hammer, tap out the oil seal from the front housing. NOTICE: Be careful not to damage the housing. R08077 Socket Wrench (b) (c) Press A A 3.4 mm (+ 3mm) Coat a new oil seal lip with power steering fluid. Using a socket wrench (23 mm), press in the oil seal as shown in the illustration. NOTICE: S Make sure you install the oil seal facing the correct direction. S Be careful not to damage the front housing. W03071 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SR−7 STEERING − STEERING WHEEL STEERING WHEEL SR168−01 INSPECTION 1. (a) R12473 CHECK STEERING WHEEL FREEPLAY With the vehicle stopped and tires pointed straight ahead, rock the steering wheel gently back and forth with light finger pressure. (b) Freeplay should not exceed the maximum. Maximum freeplay: 40 mm (1.58 in.) If the freeplay exceeds the maximum, adjust it in the following procedure. 2. (a) (b) (c) SR0097 ADJUST STEERING GEAR Point the front wheels straight ahead. Loosen the adjusting screw lock nut. Turn the cross shaft adjusting screw clockwise to decrease steering wheel freeplay and counterclockwise to increase it. HINT: Turn the adjusting screw in small increments and check the freeplay between each adjustment. (d) Turn the steering wheel half way around in both directions. (e) Check that the freeplay is correct and steering is smooth and without rough spots. (f) Torque the adjusting screw lock nut (See page SR−41). 3. (a) (b) (c) (d) CHECK STEERING EFFORT Center the steering wheel. Remove the steering wheel pad (See page SR−11). Start the engine and run it at idle. Measure the steering effort in both directions. Reference: 8.3 N·m (85 kgf·cm, 73 in.·lbf) 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 1058 Brought to you by BirfMark SR−8 STEERING − STEERING WHEEL HINT: Be sure to consider the tire type, pressure and contact surface before making your diagnosis. (e) Torque the steering wheel set nut. Torque: 34 N·m (350 kgf·cm, 25 ft·lbf) (f) Install the steering wheel pad (See page SR−19). 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 1059 Brought to you by BirfMark SR−30 STEERING Socket Wrench − POWER STEERING VANE PUMP REASSEMBLY Press R08080 Inscribed Mark R08098 SR16J−01 NOTICE: When using a vise, do not overtighten it. 1. COAT WITH POWER STEERING FLUID (See page SR−21) 2. INSTALL VANE PUMP SHAFT WITH BEARING (a) Using a socket wrench (29 mm), press in the shaft with the bearing to the front housing. NOTICE: Be careful not to damage the oil seal lip. (b) Using snap ring pliers, install a new snap ring to the front housing. 3. INSTALL LONGER STRAIGHT PIN Install a new pin to the front housing. NOTICE: Be careful not to damage the pin. 4. INSTALL SIDE FRONT PLATE (a) Coat 2 new O−rings with power steering fluid and install them to the plate. (b) Align the hole of the plate and longer straight pin. NOTICE: Make sure you install the plate facing the correct direction. (See page SR−21) 5. INSTALL SHORTER STRAIGHT PIN Install a new pin to the side front plate. NOTICE: Be careful not to damage the pin. 6. INSTALL CAM RING AND VANE PUMP ROTOR Install the ring and rotor with the inscribed marks facing outward. 7. INSTALL VANE PLATES Install the 10 plates with the round end facing outward. 8. INSTALL SIDE REAR PLATE (a) Coat a new O−ring with power steering fluid and install it to the plate. (b) Align the holes of the plate with the straight pins. Round End R08081 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SR−31 STEERING − POWER STEERING VANE PUMP 9. INSTALL WAVE WASHER Install the washer so that its protrusions fit into the slots in the side rear plate. R08069 10. (a) (b) 11. R08082 (a) (b) (c) Soft Jaws R08066 INSTALL REAR HOUSING Coat a new O−ring with power steering fluid and install it to the housing. Using a press, apply just enough pressure to compress the wave washer, and install a new snap ring to the front housing. INSTALL SPRING, FLOW CONTROL VALVE AND PRESSURE PORT UNION Install the valve facing the correct direction. (See page SR−21) Coat a new O−ring with power steering fluid and install it to the union. Torque the union. Torque: 69 N·m (700 kgf·cm, 51 ft·lbf) 12. INSTALL VANE PUMP DRIVE GEAR (a) Install the woodruff key and gear. (b) Using soft jaws on a vise, clamp the gear in the vise. NOTICE: Be careful not to damage the gear. (c) Torque the gear set nut. Torque: 74 N·m (750 kgf·cm, 54 ft·lbf) 13. MEASURE POWER STEERING PUMP ROTATING TORQUE (See page SR−24) 14. INSTALL SUCTION PORT UNION (a) Coat a new O−ring with power steering fluid and install it to the union. (b) Torque the bolt. Torque: 13 N·m (130 kgf·cm, 9 ft·lbf) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SR−32 STEERING − POWER STEERING VANE PUMP INSTALLATION 1. (a) (b) SR16K−01 INSTALL PS VANE PUMP ASSEMBLY Coat a new O−ring with power steering fluid and install it to the vane pump assembly. Torque the 2 nuts. Torque: 36 N·m (370 kgf·cm, 27 ft·lbf) R13336 Stopper R13315 2. CONNECT PRESSURE FEED TUBE Torque the union bolt with 2 new gaskets. Torque: 56 N·m (575 kgf·cm, 42 ft·lbf) HINT: Make sure the stopper of the tube is touching the PS pump body, as shown then torque the union bolt. 3. CONNECT RETURN HOSE 4. BLEED POWER STEERING SYSTEM (See page SR−3) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SR−33 STEERING − POWER STEERING GEAR POWER STEERING GEAR SR16L−01 COMPONENTS 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 1084 Brought to you by BirfMark SR−34 STEERING − POWER STEERING GEAR 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 1085 Brought to you by BirfMark SR−35 STEERING − POWER STEERING GEAR REMOVAL SR16M−01 1. PLACE FRONT WHEELS FACING STRAIGHT AHEAD 2. REMOVE STEERING WHEEL PAD (See page SR−11) 3. REMOVE STEERING WHEEL (See page SR−11) 4. REMOVE FRAME SEAL 5. REMOVE LINK JOINT PROTECTOR Remove the 2 bolts. 6. (a) (b) DISCONNECT PITMAN ARM WITH RELAY ROD Remove the pitman arm set nut and spring washer. Using SST, disconnect the pitman arm from the gear assembly. SST 09628−62011 7. DISCONNECT PRESSURE FEED AND RETURN TUBES Using SST, disconnect the pressure feed and return tubes. SST 09631−22020 8. DISCONNECT SLIDING YOKE SUB−ASSEMBLY (See page SR−13) 9. REMOVE PS GEAR ASSEMBLY Remove the 4 installation bolts and nuts. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SR−36 STEERING − POWER STEERING GEAR DISASSEMBLY SR16N−01 NOTICE: When using a vise, do not overtighten it. 1. SECURE PS GEAR ASSEMBLY IN VISE Secure the gear assembly on SST and clamp SST in a vise. SST 09630−00014 (09631−00142) 2. REMOVE ADJUSTING SCREW LOCK NUT AND SEAL WASHER 3. (a) (b) (c) REMOVE SIDE COVER Remove the 4 bolts. Turn the cross shaft adjusting screw clockwise until the cover comes off. Remove the O−ring from the cover. 4. REMOVE CROSS SHAFT Using a plastic hammer, tap on the cross shaft end and pull out the shaft. 5. (a) (b) 6. (a) (b) REMOVE POWER PISTON PLUNGER GUIDE NUT, COMPRESSION SPRING, POWER PISTON PLUNGER AND POWER PISTON PLUNGER GUIDE Using a hexagon wrench (10 mm), remove the plunger guide nut. Remove the O−ring from the plunger guide nut. REMOVE WORM GEAR VALVE BODY ASSEMBLY Remove the 4 bolts. Using SST, turn the valve body shaft clockwise with holding the worm gear by your finger so it cannot move. SST 09616−00010 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SR−37 STEERING − POWER STEERING GEAR (c) Pull out the valve body assembly. NOTICE: Ensure that the worm gear does not come off the worm shaft. (d) Remove the 2 O−rings from the gear housing. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SR−38 STEERING Dial Indicator 30 mm (1.18 in.) − POWER STEERING GEAR INSPECTION SR16O−01 NOTICE: When using a vise, do not overtighten it. 1. INSPECT BALL CLEARANCE Using a dial indicator, check the ball clearance. Move the worm gear up and down. Maximum clearance: 0.15 mm (0.0059 in.) Z14503 2. Dial Indicator INSPECT CROSS SHAFT ADJUSTING SCREW THRUST CLEARANCE Using a dial indicator, measure the thrust clearance. Standard clearance: 0.03 − 0.05 (0.0012 − 0.0020 in.) Z14504 3. (a) IF NECESSARY, ADJUST CROSS SHAFT ADJUSTING SCREW THRUST CLEARANCE Using a chisel and hammer, unstake the No.1 lock nut. Z10600 (b) (c) (d) (e) 4. (a) (b) (c) Using SST, remove the No.1 lock nut. SST 09630−00014 (09631−00051) Using a screwdriver, adjust the adjusting screw for correct thrust clearance. Using the SST, tighten a new lock nut. Using a chisel and hammer, stake the lock nut. IF NECESSARY, REPLACE OIL SEAL, METAL SPACER AND TEFLON RING Using a screwdriver, pry out the oil seal from the gear housing. Using snap ring pliers, remove the snap ring from the gear housing. Remove the metal spacer, teflon ring and O−ring from the gear housing. Z06211 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SR−39 STEERING − POWER STEERING GEAR (d) Coat a new O−ring and metal spacer with power steering fluid and install them. (e) Using snap ring pliers, install a new snap ring. (f) Coat a new teflon ring with power steering fluid. (g) Form a teflon ring into a heart shape and install it with hand. (h) Using SST, form the teflon ring. SST 09630−00014 (09631−00121) NOTICE: The teflon ring must be squeezed before inserting the cross shaft or damage will result. (i) (j) Coat a new oil seal with power steering fluid. Using SST, press in the oil seal to the gear housing. SST 09950−60010 (09951−00340, 09951−00450) 09950−70010 (09951−07200) NOTICE: Make sure you install the oil seal facing the correct direction. 5. IF NECESSARY, REPLACE TEFLON RING AND O− RING (a) Using a screwdriver, remove the teflon ring and O−ring from the worm gear valve body assembly. NOTICE: Be careful not to damage the worm gear valve body assembly. (b) Coat a new O−ring with power steering fluid and install it. (c) Expand a new teflon ring with your fingers. NOTICE: Be careful not to overexpand the teflon ring. (d) Install the teflon ring. (e) Coat the teflon ring with power steering fluid and snug it down with piston ring compressor for 5 − 7 minutes. SR2804 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SR−40 STEERING 6. (a) − POWER STEERING GEAR IF NECESSARY, REPLACE UNION SEATS Using a screw extractor, remove the 2 union seats from the worm gear valve body assembly. (b) Using a hammer and extension bar, tap in 2 new union seats. NOTICE: Before installing the union seat, remove dust sticking to the worm gear valve body assembly. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SR−41 STEERING − POWER STEERING GEAR REASSEMBLY SR16P−01 NOTICE: When using a vise, do not overtighten it. 1. COAT WITH MOLYBDENUM DISULFIDE LITHIUM BASE GREASE (See page SR−33) 2. INSTALL WORM GEAR VALVE BODY ASSEMBLY (a) Coat 2 new O−rings with power steering fluid and install them to the gear housing. (b) Secure the gear housing on SST and clamp SST in vise. SST 09630−00014 (09631−00142) (c) Install the valve body assembly while supporting the worm gear with your fingers so that it does not rotate. (d) Torque the 4 bolts. Torque: 61 N·m (620 kgf·cm, 45 ft·lbf) NOTICE: Be careful not to damage the teflon ring. (e) Using SST and a torque wrench, check the valve body assembly rotating torque. SST 09616−00010 Rotating torque: 0.3 − 0.5 N·m (3 − 5.5 kgf·cm, 2.6 − 4.8 in.·lbf) HINT: Hold the worm gear to prevent it from turning. If rotating torque is not correct, replace the worm gear valve body assembly. 3. (a) (b) INSTALL POWER PISTON PLUNGER GUIDE, POWER PISTON PLUNGER, COMPRESSION SPRING AND POWER PISTON PLUNGER GUIDE NUT Coat a new O−ring with power steering fluid. Install the O−ring to the plunger guide nut and install the plunger guide nut with a hexagon wrench (10 mm). Torque: 20 N·m (205 kgf·cm, 15 ft·lbf) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SR−42 STEERING 4. (a) (b) 5. (a) − POWER STEERING GEAR DETERMINE CENTER POSITION Using SST, turn the worm gear valve body shaft so full lock in both directions and determine the exact center. SST 09616−00010 Place matchmarks on the worm gear valve body shaft and worm gear valve body housing to show neutral position. INSTALL CROSS SHAFT AND SIDE COVER Coat a new O−ring with power steering fluid and install it on the side cover. Assemble the cross shaft to the side cover. (b) HINT: Fully loosen the cross shaft adjusting screw. (c) Install and push the cross shaft into the gear housing so that the center teeth mesh together. (d) Torque the 4 bolts in a diagonal pattern. Torque: 61 N·m (620 kgf·cm, 45 ft·lbf) 6. ADJUST TOTAL PRELOAD (a) Install SST with a torque wrench on the worm gear valve body shaft. SST 09616−00010 (b) Turn the cross shaft adjusting screw until the preload is within specification. Preload (Turning): 0.74 − 10.8 N·m (7.5 − 11.0 kgf·cm, 6.5 − 9.6 in.·lbf) 7. INSTALL NEW SEAL WASHER 8. INSTALL ADJUSTING SCREW LOCK NUT Torque the lock nut while holding the cross shaft adjusting screw. Torque: 46 N·m (470 kgf·cm, 34 ft·lbf) 9. CHECK TOTAL PRELOAD Using SST and a torque wrench, check total preload. SST 09616−00010 Total preload (Turning): 0.74 − 1.08 N·m (7.5 − 11.0 kgf·cm, 6.5 − 9.6 in.·lbf) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SR−43 STEERING − POWER STEERING GEAR INSTALLATION SR16Q−01 1. INSTALL PS GEAR ASSEMBLY Torque the 4 installation bolts and nuts. Torque: 142 N·m (1,450 kgf·cm, 105 ft·lbf) 2. CONNECT SLIDING YOKE SUB−ASSEMBLY (See page SR−19) 3. CONNECT PRESSURE FEED AND RETURN TUBES Using SST, connect the pressure feed and return tubes. SST 09631−22020 Torque: 36 N·m (365 kgf·cm, 26 ft·lbf) HINT: S Use a torque wrench with a fulcrum length of 300 mm (11.81 in.). S This torque value is effective in case that SST is parallel to a torque wrench. 4. (a) Alignment Marks (b) 5. SR2922 CONNECT PITMAN ARM WITH RELAY ROD Align the alignment marks on the cross shaft and pitman arm and connect the pitman arm. Install the spring washer and pitman arm set nut. Torque: 177 N·m (1,800 kgf·cm, 130 ft·lbf) POSITION FRONT WHEELS FACING STRAIGHT AHEAD HINT: Do it with the front of the vehicle jacked up. 6. CENTER SPIRAL CABLE (See page SR−19) 7. INSTALL STEERING WHEEL (a) Align the matchmarks on the wheel and steering column main shaft. (b) Temporarily tighten the wheel set nut. (c) Connect the connector. 8. BLEED POWER STEERING SYSTEM (See page SR−3) 9. CHECK STEERING WHEEL CENTER POINT 10. TORQUE STEERING WHEEL SET NUT Torque: 34 N·m (350 kgf·cm, 25 ft·lbf) 11. INSTALL STEERING WHEEL PAD (See page SR−19) 12. CHECK FRONT WHEEL ALIGNMENT (See page SR−4) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SR−44 STEERING − STEERING LINKAGE STEERING LINKAGE SR16R−01 COMPONENTS 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 1095 Brought to you by BirfMark SR−45 STEERING − STEERING LINKAGE REMOVAL SR16S−03 NOTICE: When using a vise, do not overtighten it. 1. REMOVE ENGINE UNDER COVER Remove the 4 bolts. 2. REMOVE PITMAN ARM (a) Remove the cotter pin and nut. (b) SST (c) Using SST, disconnect the pitman arm from the relay rod assembly. SST 09611−22012 Remove the pitman arm set nut and spring washer. SR4102 (d) 3. (a) (b) SST 4. (a) (b) Using SST, disconnect the pitman arm from the PS gear assembly. SST 09628−62011 REMOVE STEERING DAMPER WITH STEERING DAMPER BRACKET Remove the nut and 2 damper bracket set bolts. Using SST, disconnect the damper with damper bracket from the relay rod assembly. SST 09611−22012 REMOVE STEERING DAMPER Secure the damper bracket in a vise. Remove the nut. SR4103 SST (c) Using SST, remove the damper from the damper bracket. SST 09610−55012 5. (a) REMOVE RELAY ROD ASSEMBLY Remove the cotter pin and nut. SR4104 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SR−46 STEERING (b) 6. (a) − STEERING LINKAGE Using SST, disconnect the relay rod assembly from the knuckle arm. SST 09611−22012 REMOVE TIE ROD ASSEMBLY Remove the 2 cotter pins and nuts. (b) SST Using SST, disconnect the tie rod assembly from the RH and LH knuckle arms. SST 09611−22012 7. REMOVE TIE ROD ENDS AND RELAY ROD ENDS Loosen the tie rod end or relay rod end clamp and remove the tie rod end or relay rod end. SR4106 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SR−47 STEERING − STEERING LINKAGE INSTALLATION SR16T−01 HINT: When connecting the ball stud to the arm or rod, remove the grease on the joint surfaces. 1. INSTALL TIE ROD ENDS AND RELAY ROD ENDS (a) Turn the tie rod ends or relay rod ends equal amounts into the rod tube. Tie rod assembly should be approximately 1,233 mm (48.54 in.). Relay rod assembly should be approximately 1,090 mm (42.91 in.). (b) The remaining length of threads on both tie rod ends or relay rod ends should be equal. (c) Temporarily tighten the tie rod end or relay rod end clamps. 2. INSTALL TIE ROD ASSEMBLY (a) Connect the tie rod assembly to the RH and LH knuckle arms. (b) Torque the 2 nuts. Torque: 91 N·m (925 kgf·cm, 67 ft·lbf) (c) Install 2 new cotter pins. (d) After adjusting toe−in, torque the clamp bolts and nuts. Torque: 37 N·m (375 kgf·cm, 27 ft·lbf) 3. INSTALL RELAY ROD ASSEMBLY (a) Connect the relay rod assembly to the knuckle arm. (b) Torque the nut. Torque: 91 N·m (925 kgf·cm, 67 ft·lbf) (c) Install a new cotter pin. (d) Torque the clamp bolts and nuts. Torque: 37 N·m (375 kgf·cm, 27 ft·lbf) 4. INSTALL STEERING DAMPER (a) Secure the damper bracket in a vise. (b) Connect the damper to the damper bracket. (c) Torque a new nut. Torque: 74 N·m (750 kgf·cm, 54 ft·lbf) 5. INSTALL STEERING DAMPER WITH STEERING DAMPER BRACKET (a) Connect the damper with damper bracket to the relay rod assembly. (b) Torque a new nut and 2 damper bracket set bolts. Torque: Nut: 74 N·m (750 kgf·cm, 54 ft·lbf) Bolt: 39 N·m (400 kgf·cm, 29 ft·lbf) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SR−48 STEERING − STEERING LINKAGE 6. (a) Alignment Marks SR2922 INSTALL PITMAN ARM Align the alignment marks on the pitman arm and the cross shaft, and install the spring washer and set nut. Torque: 177 N·m (1,800 kgf·cm, 130 ft·lbf) (b) Connect the pitman arm to the relay rod assembly. (c) Torque the nut. Torque: 91 N·m (925 kgf·cm, 67 ft·lbf) (d) Install a new cotter pin. 7. INSTALL ENGINE UNDER COVER Tighten the 4 bolts. 8. CHECK FRONT WHEEL ALIGNMENT (See page SA−4) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SS−1 SERVICE SPECIFICATIONS − STANDARD BOLT STANDARD BOLT SS00F−01 HOW TO DETERMINE BOLT STRENGTH Mark Hexagon head bolt Class 4− 4T 5− 5T 6− 6T 7− 8− 7T 8T 9− 10− 9T Bolt head No. 11− No mark 10T 11T Hexagon head bolt Hexagon flange bolt w/ washer hexagon bolt Hexagon head bolt Hexagon head bolt Hexagon flange bolt w/ washer hexagon bolt Hexagon flange bolt w/ washer hexagon bolt Hexagon flange bolt 4T Hexagon flange bolt w/ washer hexagon bolt Mark w/ washer hexagon bolt Stud bolt No mark Class 4 Protruding lines 9T 5 Protruding lines 10T 6 Protruding lines 11T No mark 4T 4T 2 Protruding lines 5T 2 Protruding lines 6T 3 Protruding lines 7T 4 Protruding lines Grooved 6T Welded bolt 4T 8T V06821 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 124 Brought to you by BirfMark SS−2 SERVICE SPECIFICATIONS − STANDARD BOLT SS00G−01 SPECIFIED TORQUE FOR STANDARD BOLTS Class Diameter mm Pitch mm Specified torque Hexagon head bolt Hexagon flange bolt N·m kgf·cm kgf·cm ft·lbf N·m ft·lbf in.·lbf in.·lbf in.·lbf in.·lbf in.·lbf in.·lbf V00079 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SS−3 SERVICE SPECIFICATIONS − MAINTENANCE MAINTENANCE SS1EN−01 TORQUE SPECIFICATION Part tightened Front seat mounting bolt N·m kgf·cm ft·lbf 39 400 29 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 126 Brought to you by BirfMark SS−4 SERVICE SPECIFICATIONS − ENGINE MECHANICAL ENGINE MECHANICAL SS1EO−04 SERVICE DATA Compression pressure at 250 rpm STD 1,176 kPa (12.0 kgf/cm2, 171 psi) or more Minimum 883 kPa (9.0 kgf/cm2, 128 psi) Difference of pressure between each cylinder 98 kPa (1.0 kgf/cm2, 14 psi) or less Valve clearance at cold Intake Exhaust Ignition timing w/ Terminals TE1 and E1 connected Idle speed Cylinder head − Warpage Cylinder block side Manifold side Valve seat Refacing angle Maximum 0.15 mm (0.0059 in.) Maximum 0.10 mm (0.0039 in.) Intake 30°, 45°, 75° Exhaust 45°, 75° 45° Intake 1.2 − 1.6 mm (0.047 − 0.063 in.) Exhaust 1.0 − 1.4 mm (0.039 − 0.055 in.) STD 10.85 − 11.00 mm (0.4272 − 0.4331 in.) Minimum 10.6 mm (0.417 in.) Cylinder head bolt outside diameter Inside diameter Outside diameter (for repair part) STD O/S 0.05 Protrusion height Valve 3° BTDC @ idle 650 ± 50 rpm Contacting angle Contacting width Valve guide bushing 0.15 − 0.25 mm (0.006 − 0.010 in.) 0.25 − 0.35 mm (0.010 − 0.014 in.) Valve overall length 7.010 − 7.030 mm (0.2760 − 0.2768 in.) 11.492 − 11.513 mm (0.4524 − 0.4533 in.) 11.542 − 11.563 mm (0.4544 − 0.4522 in.) 8.2 − 8.6 mm (0.323 − 0.339 in.) STD Intake Exhaust Minimum Intake Exhaust 98.4 mm (3.874 in.) 97.9 mm (3.854 in.) 97.9 mm (3.854 in.) 97.4 mm (3.835 in.) 44.5° Intake 6.970 − 6.985 mm (0.2744 − 0.2750 in.) Exhaust 6.965 − 6.980 mm (0.2742 − 0.2748 in.) STD Intake 0.025 − 0.060 mm (0.0010 − 0.0024 in.) Exhaust 0.030 − 0.065 mm (0.0012 − 0.0026 in.) Maximum Intake 0.08 mm (0.0031 in.) Exhaust 0.10 mm (0.0039 in.) STD 1.2 mm (0.047 in.) Minimum 1.0 mm (0.039 in.) Valve face angle Stem diameter Stem oil clearance Margin thickness Valve spring Deviation Free length Installed tension at 36.5 mm (1.437 in.) Maximum 2.0 mm (0.079 in.) 43.94 − 45.06 mm (1.7299 − 1.7740 in.) 214 − 238 N (21.8 − 24.2 kgf, 48.1 − 53.4 lbf) Valve lifter Lifter diameter Lifter bore diameter Oil clearance 33.966 − 33.976 mm (1.3372 − 1.3376 in.) 34.000 − 34.021 mm (1.3386 − 1.3394 in.) STD 0.024 − 0.055 mm (0.0009 − 0.0022 in.) Maximum 0.07 mm (0.0028 in.) Manifold Warpage Maximum 0.30 mm (0.0118 in.) Air intake chamber Warpage Maximum 0.30 mm (0.0118 in.) 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 127 Brought to you by BirfMark SS−5 SERVICE SPECIFICATIONS Camshaft Thrust clearance − ENGINE MECHANICAL STD Maximum STD Maximum Journal oil clearance Journal diameter Circle runout Cam lobe height Camshaft gear backlash Camshaft gear spring end free distance 0.030 − 0.080 mm (0.0012 − 0.0031 in.) 0.10 mm (0.0039 in.) 0.025 − 0.062 mm (0.0010 − 0.0024 in.) 0.10 mm (0.0039 in.) 26.959 − 26.975 mm (1.0614 − 1.0620 in.) Maximum 0.06 mm (0.0024 in.) STD 50.61 − 50.71 mm (1.9925 − 1.9965 in.) Minimum 50.51 mm (1.9886 in.) STD 0.020 − 0.200 mm (0.0008 − 0.0079 in.) Maximum 0.30 mm (0.0188 in.) 18.2 − 18.8 mm (0.712 − 0.740 in.) Spark plug tube Protrusion Oil pump drive shaft gear Thrust clearance STD 0.040 − 0.160 mm (0.0016 − 0.0063 in.) Maximum 0.30 mm (0.0188 in.) Chain and timing gear Chain length at 16 links Camshaft timing gear wear (w/ Chain) Crankshaft timing gear wear (w/ Chain) Maximum 146.6 mm (5.772 in.) Minimum 126.0 mm (4.961 in.) Minimum 65.4 mm (2.575 in.) Chain tensioner slipper and vibration damper Wear Maximum 1.0 mm (0.039 in.) Cylinder block Cylinder head surface warpage Cylinder bore diameter Main bearing bolt outside diameter Piston and piston ring Piston diameter Piston oil clearance Piston ring groove clearance Piston ring end gap 45.5 mm (1.791 in.) Maximum STD Mark 1 2 3 Maximum STD O/S 0.50 O/S 1.00 STD Minimum 0.05 mm (0.0020 in.) 100.000 − 100.010 mm (3.9370 − 3.9374 in.) 100.010 − 100.020 mm (3.9374 − 3.9378 in.) 100.020 − 100.030 mm (3.9378 − 3.9382 in.) 100.23 mm (3.9461 in.) 100.73 mm (3.9658 in.) 101.23 mm (3.9854 in.) 10.85 − 11.00 mm (0.4271 − 0.4331 in.) 10.6 mm (0.417 in.) STD Mark 1 2 3 O/S 0.50 O/S 1.00 STD No. 1 No. 2 STD No. 1 No. 2 Oil Maximum No. 1 No. 2 Oil 99.950 − 99.960 mm (3.9350 − 3.9354 in.) 99.960 − 99.970 mm (3.9354 − 3.9358 in.) 99.970 − 99.980 mm (3.9358 − 3.9362 in.) 100.450 − 100.480 mm (3.9547 − 3.9559 in.) 100.950 − 100.980 mm (3.9744 − 3.9756 in.) 0.040 − 0.060 mm (0.0016 − 0.0024 in.) 0.040 − 0.080 mm (0.0016 − 0.0031 in.) 0.300 − 0.070 mm (0.0012 − 0.0028 in.) 0.300 − 0.520 mm (0.0118 − 0.0205 in.) 0.450 − 0.670 mm (0.0177 − 0.0264 in.) 0.150 − 0.520 mm (0.0059 − 0.0205 in.) 1.12 mm (0.0441 in.) 1.17 mm (0.0461 in.) 1.12 mm (0.0441 in.) 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 128 Brought to you by BirfMark SS−6 SERVICE SPECIFICATIONS Connecting rod Crankshaft − ENGINE MECHANICAL Thrust clearance STD Maximum Connecting rod bearing center wall thickness (Reference) Mark 2 3 4 5 6 Connecting rod oil clearance STD STD U/S 0.25 Maximum Rod bend Maximum per 100 mm (3.94 in.) Rod twist Maximum per 100 mm (3.94 in.) Bushing inside diameter Piston pin diameter Piston pin oil clearance STD Maximum Connecting rod bolt outside diameter STD Minimum Thrust clearance STD Maximum Thrust washer thickness STD O/S 0.125 O/S 0.250 Main journal oil clearance STD STD U/S 0.25 Maximum Main journal diameter STD U/S 0.25 Main bearing center wall thickness (Reference) Mark 2 3 4 5 6 Crank pin diameter STD U/S 0.25 Circle runout Maximum Main journal taper and out−of−round Maximum Crank pin taper and out−of−round Maximum 0.160 − 0.262 mm (0.0063 − 0.0103 in.) 0.362 mm (0.0143 in.) 1.744 − 1.747 mm (0.0687 − 0.0688 in.) 1.747 − 1.750 mm (0.0688 − 0.0689 in.) 1.750 − 1.753 mm (0.0689 − 0.0690 in.) 1.753 − 1.756 mm (0.0690 − 0.0691 in.) 1.756 − 1.759 mm (0.0691 − 0.0693 in.) 0.032 − 0.050 mm (0.0013 − 0.0020 in.) 0.033 − 0.073 mm (0.0013 − 0.0029 in.) 0.10 mm (0.0039 in.) 0.05 mm (0.0020 in.) 0.015 mm (0.0059 in.) 26.008 − 26.020 mm (1.0239 − 1.0244 in.) 26.000 − 22.012 mm (1.0236 − 1.0241 in.) 0.004 − 0.012 mm (0.0002 − 0.0005 in) 0.05 mm (0.0020 in.) 8.40 − 8.60 mm (0.3307 − 0.3386 in.) 8.00 mm (0.3150 in.) 0.020 − 0.220 mm (0.0008 − 0.0087 in.) 0.30 mm (0.0118 in.) 2.440 − 2.490 mm (0.0961 − 0.0980 in.) 2.503 − 2.553 mm (0.0985 − 0.1005 in.) 2.565 − 2.615 mm (0.1010 − 0.1030 in.) 0.042 − 0.060 mm (0.0017 − 0.0024 in.) 0.041 − 0.081 mm (0.0016 − 0.0032 in.) 0.10 mm (0.0039 in.) 68.982 − 69.000 mm (2.7158 − 2.7165 in.) 68.745 − 68.755 mm (2.7065 − 2.7069 in.) 2.489 − 2.492 mm (0.0980 − 0.0981 in.) 2.492 − 2.495 mm (0.0981 − 0.0982 in.) 2.495 − 2.498 mm (0.0982 − 0.0983 in.) 2.498 − 2.501 mm (0.0983 − 0.0985 in.) 2.501 − 2.504 mm (0.0985 − 0.0986 in.) 56.982 − 57.000 mm (2.2434 − 2.2441 in.) 56.745 − 56.755 mm (2.2341 − 2.2344 in.) 0.06 mm (0.0024 in.) 0.02 mm (0.0008 in.) 0.02 mm (0.0008 in.) 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 129 Brought to you by BirfMark SS−7 SERVICE SPECIFICATIONS − ENGINE MECHANICAL SS1EP−01 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf Distributor x Cylinder head 18 180 13 No. 1 engine hanger x Cylinder head 41 420 30 No. 2 engine hanger x Cylinder head 41 420 30 Air intake chamber x Intake manifold 21 210 15 Intake manifold x Cylinder head 21 210 15 Heater inlet pipe x Intake manifold 21 210 15 EGR pipe x Cylinder head 21 210 15 78 800 58 21 210 15 43 440 32 39 Turn 90° Turn 90° 400 Turn 90° Turn 90° 29 Turn 90° Turn 90° Cylinder head x Timing chain cover 21 210 15 Camshaft bearing cap x Cylinder head 16 160 12 Camshaft timing gear x Camshaft 74 750 54 Chain tensioner x Cylinder head 21 210 15 Water bypass outlet x Cylinder head 21 210 15 Heater pipe x Timing chain cover 21 210 15 Heater pipe x Cylinder head 20 200 14 Exhaust manifold x Cylinder head 39 400 29 Heat insulator x Exhaust manifold 19 195 14 Front exhaust pipe x Exhaust manifold 63 630 46 No. 1 support bracket x Transmission 24 240 17 No. 1 support bracket clamp bolt 19.5 195 14 Front exhaust pipe x Rear TWC 46 470 34 No. 2 water bypass pipe x Cylinder head 20 200 14 No. 2 water bypass pipe x No. 1 engine hanger 20 200 14 Fuel inlet hose x Fuel filter 29 300 22 Intake manifold stay x Air intake chamber 36 360 26 Intake manifold stay x Cylinder block 36 360 26 Oil dipstick guide x Intake manifold 20 200 14 Oil dipstick guide x No. 1 oil pan 20 200 14 PS reservoir tank x Air intake chamber 20 200 14 Oil jet x Cylinder block 20 200 14 Vibration damper x Cylinder block 20 200 14 Chain tensioner slipper x Cylinder block 69 700 51 Timing chain cover x Cylinder block 21 210 15 Drive belt idler pulley x Timing chain cover 43 440 32 Crankshaft pulley x Crankshaft 412 4,200 304 Transmission housing x No. 1 oil pan 72 730 53 Oil level sensor x No. 1 oil pan 5.4 55 48 in.·lbf Water pump x Cylinder block 21 210 15 Radiator pipe x No. 1 oil pan 21 210 15 EGR pipe x EGR valve Union nut Water outlet x Cylinder head Generator bracket x Cylinder head Cylinder head x Cylinder block 1st 2nd 3rd 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SS−8 SERVICE SPECIFICATIONS − ENGINE MECHANICAL A/C compressor bracket x No. 1 oil pan 37 375 27 A/C compressor bracket x Cylinder block 37 375 27 A/C compressor x A/C compressor bracket 25 250 18 Oil check valve x Cylinder block 25 250 18 Main bearing cap x Cylinder block 1st 2nd 74 Turn 90° 750 Turn 90° 54 Turn 90° Connecting rod cap x Connecting rod 1st 2nd 48 Turn 90° 490 Turn 90° 35 Turn 90° Rear oil seal retainer x Cylinder block 21 210 15 Oil cooler cover x Cylinder block 21 210 15 LH engine mounting bracket x Cylinder block 69 700 51 LH insulator x LH engine mounting bracket 72 730 43 RH engine mounting bracket x Cylinder brock 69 700 51 RH insulator x RH engine mounting bracket 72 730 43 PS pump x Cylinder block 36 370 27 Knock sensor x Cylinder block 44 450 33 Oil filter union x Cylinder block 44 450 33 Drive plate x Crankshaft 100 1,000 74 Transmission x Cylinder block 72 730 53 Transmission x No. 1 oil pan 72 730 53 Torque converter clutch x Drive plate 55 550 41 A/T oil cooler pipe x Union (Transmission) 34 350 25 Starter x Transmission 39 400 29 Frame crossmember x Frame 61 620 45 Frame crossmember x Engine rear mounting insulator 74 750 54 Engine front mounting insulator x Frame 74 750 54 Transfer shift lever x Transmission 18 185 13 Transmission shift lever assembly x Body 5.4 55 48 in.·lbf Transmission control rod x Control shaft lever 13 130 9 Front propeller shaft x Front differential 74 750 54 Front propeller shaft x Transfer 74 750 54 Rear propeller shaft x Rear differential 88 900 65 Rear propeller shaft x Transfer 88 900 65 Stabillizer bar bracket mounting bolt 18 185 13 Stabillizer bar x Axle carrier 25 260 19 PS pressure hose x PS pump 56 575 42 Rear TWC x Center pipe 40 400 29 Center pipe x Tailpipe 40 400 29 Heated oxygen sensor (Bank 1 sensor 1) x Front exhaust pipe 20 200 14 Heated oxygen sensor (Bank 1 sensor 2) x Center pipe 20 200 14 No. 2 support bracket x Frame 18.5 185 13 No. 3 support bracket x Frame 18.5 185 13 No. 4 support bracket x Frame 18.5 185 13 Exhaust pipe damper x Tailpipe 19.5 195 14 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SS−9 SERVICE SPECIFICATIONS − EMISSION CONTROL EMISSION CONTROL SS1EQ−01 SERVICE DATA VSV for EVAP Resistance at 20°C (68°F) 30 − 34 Ω 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 132 Brought to you by BirfMark SS−10 SERVICE SPECIFICATIONS − EMISSION CONTROL SS1ER−01 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf Charcoal canister x Charcoal canister bracket 14 145 10 Charcoal canister bracket x Body 18 185 13 TVV x Cylinder head 29 300 22 Intake manifold stay x Air intake chamber 36 360 26 Intake manifold stay x Cylinder block 36 360 26 9 18 90 180 78 in.·lbf 13 EGR valve x EGR pipe 64 650 47 EGR valve x EGR vacuum modulator 18 185 13 EGR valve x Air intake chamber for stud bolt for nut 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SS−11 SERVICE SPECIFICATIONS − SFI SFI SS1ES−01 SERVICE DATA at no vacuum 265 − 304 kPa (2.7 − 3.1 kgf/cm2, 38 − 44 psi) Fuel pressure regulator Fuel pressure Fuel pump Resistance at 20°C (68°F) 0.2 − 3.0 Ω Injector Resistance Injection volume Difference between each cylinder Fuel leakage at 20°C (68°F) 13.4 − 14.2 Ω 69 − 88 cm3 (4.2 − 5.4 cu in.) per 15 sec. 5 cm3 (0.3 cu in.) or less 1 drop or less per 12 min. MAF meter Resistance (THA − E2) Throttle body Throttle body fully closed angle Dashpot setting speed Throttle opener setting speed Throttle position sensor Clearance between stop screw and lever 0 mm (0 in.) 0.50 mm (0.020 in.) 0.75 mm (0.030 in.) Throttle valve fully open − IAC valve Resistance (B1 − S1 and S3, B2 − S2 and S4) at cold (−10 − 50 °C (−50 − 122°F)) at hot (50 − 100°C (122 − 212°F)) 15 − 25 Ω 20 − 30 Ω Fuel pump resistor Resistance at 20°C (68°F) 0.70 − 0.76 Ω VSV for fuel pressure control Resistance at 20°C (68°F) 37 − 44 Ω ECT sensor Resistance at −20°C (−4°F) 0°C (32°F) 20°C (68°F) 40°C (104°F) 60°C (140°F) 80°C (176°F) 10 − 20 kΩ 4 − 7 kΩ 2 − 3 kΩ 0.9 − 1.3 kΩ 0.4 − 0.7 kΩ 0.2 − 0.4 kΩ EGR gas temp sensor Resistance at 50°C (122°F) at 100°C (212°F) 150°C (302°F) 64 − 97 kΩ 11 − 16 kΩ 2 − 4 kΩ Heated oxygen sensor Heater coil resistance Fuel cut rpm Fuel return rpm at −20°C (−4°F) at 0°C (32°F) at 20°C (68°F) at 40°C (104°F) at 60°C (140°F) at 80°C (176°F) 10 − 20 kΩ 4 − 7 kΩ 2 − 3 kΩ 0.9 − 1.3 kΩ 0.4 − 0.7 kΩ 0.2 − 0.4 kΩ 6° 2,200 ± 300 rpm 700 − 1,000 rpm VTA − E2 IDL − E2 IDL − E2 VTA − E2 VC − E2 at 20°C (68°F) 0.2 − 5.7 kΩ 2.3 kΩ or less Infinity 2.0 − 10.2 kΩ 2.5 − 5.9 kΩ 11 − 16 Ω 1,200 rpm 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 134 Brought to you by BirfMark SS−12 SERVICE SPECIFICATIONS − SFI SS1ET−01 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf 29 30 300 310 22 22 Second seat x Body 39 400 29 Fuel pump bracket assembly x Fuel tank 3.9 40 35 in.·lbf Fuel inlet hose x Fuel filter 29 300 22 Fuel inlet pipe x Fuel filter 29 300 22 Fuel filter x Intake manifold 21 210 15 Fuel pressure regulator x Delivery pipe 25 250 18 Delivery pipe x Intake manifold 21 210 15 29 20 300 200 22 14 Fuel inlet pipe x Fuel filter 29 300 22 Fuel return pipe x Intake manifold 20 200 14 Air intake chamber x Intake manifold 21 210 15 Intake manifold stay x Air intake chamber 36 360 26 Intake manifold stay x Cylinder block 36 360 26 PS reservoir tank x Air intake chamber 18 185 13 Heater inlet pipe x Air intake chamber 20 200 14 Drain plug x Fuel tank 6.5 65 57 in.·lbf Fuel tank breather tube x Fuel tank 1.5 15 13 in.·lbf Fuel tank filler pipe x Fuel tank 3.5 35 31 in.·lbf Fuel tank band x Body 39 400 29 MAF meter x Bracket 6.9 70 61 in.·lbf MAF meter x Air cleaner cap 6.9 70 61 in.·lbf Throttle body x Air intake chamber 21 210 15 Fuel pump resistor x Body 18 185 13 24.5 250 17.5 EGR gas temperature sensor x Air intake chamber 20 200 14 Knock sensor x Cylinder block 44 450 33 Fuel line Fuel inlet pipe x Delivery pipe ECT sensor x Cylinder head for union bolt for flare nut Union bolt Bolt 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SS−13 SERVICE SPECIFICATIONS − COOLING COOLING SS1EU−01 SERVICE DATA Thermostat Radiator cap Valve opening temperature Valve lift Relief valve opening pressure at 95°C (203°F) 80 − 84°C (176 − 183°F) 10 mm (0.39 in.) or more STD 74 − 103 kPa (0.75 − 1.05 kgf/cm2, 10.7 − 14.9 psi) Minimum 59 kPa (0.6 kgf/cm2, 8.5 psi) 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 136 Brought to you by BirfMark SS−13 SERVICE SPECIFICATIONS − COOLING COOLING SS1EU−01 SERVICE DATA Thermostat Radiator cap Valve opening temperature Valve lift Relief valve opening pressure at 95°C (203°F) 80 − 84°C (176 − 183°F) 10 mm (0.39 in.) or more STD 74 − 103 kPa (0.75 − 1.05 kgf/cm2, 10.7 − 14.9 psi) Minimum 59 kPa (0.6 kgf/cm2, 8.5 psi) 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 136 Brought to you by BirfMark SS−15 SERVICE SPECIFICATIONS − LUBRICATION LUBRICATION SS1EW−01 SERVICE DATA Oil pressure Oil pump at idle speed at 3,000 rpm Body clearance Side clearance Tip clearance STD Maximum STD Maximum STD Maximum 29 kPa (0.3 kgf/cm2, 4.3 psi) or more 245 − 490 kPa (2.5 − 5.0 kgf/cm2, 36 − 71 psi) 0.100 − 0.170 mm (0.0039 − 0.0067 in.) 0.30 mm (0.0118 in.) 0.030 − 0.090 mm (0.0012 − 0.0035 in.) 0.15 mm (0.0059 in.) 0.030 − 0.160 mm (0.0012 − 0.0063 in.) 0.25 mm (0.0098 in.) 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 138 Brought to you by BirfMark SS−16 SERVICE SPECIFICATIONS − LUBRICATION SS1EX−04 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf Oil pan x Drain plug 25 250 18 Oil pump x Relief valve plug 49 500 36 Drive belt idler pulley x Oil pump 43 440 32 Oil strainer x No. 1 oil pan 20 200 14 Baffle plate x No. 1 oil pan 9.0 90 78 in.·lbf 44 20 440 200 32 14 20 200 14 7.8 8.8 80 90 69 in.·lbf 78 in.·lbf No. 1 oil pan x Transmission housing 72 730 53 Oil level sensor x No. 1 oil pan 5.4 55 48 in.·lbf Water pump x Cylinder block 21 210 15 Radiator pipe x No. 1 oil pan 21 210 15 A/C compressor bracket x No. 1 oil pan 37 375 27 A/C compressor bracket x Cylinder block 37 375 27 A/C compressor x A/C compressor bracket 25 250 18 Oil cooler cover x Relief valve plug 37 375 27 Oil cooler x Oil cooler cover 17 170 12 Oil cooler cover x Cylinder block 21 210 15 No. 1 exhaust manifold x Cylinder head 39 400 29 No. 1 exhaust manifold x Heat insulator 19 195 14 Front exhaust pipe x Exhaust manifold 63 630 46 No. 1 support bracket x Transmission housing 24 240 17 19.5 195 14 Front exhaust pipe x Rear TWC 46 470 34 Oil check valve x Cylinder block 25 250 18 No. 1 oil pan x Cylinder block 14 mm head bolt 12 mm head bolt No. 1 oil pan x Oil pump (Timing chain cover) No. 2 oil pan x No. 1 oil pan Front exhaust pipe x No. 1 support bracket Bolt Nut Clamp bolt 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SS−17 SERVICE SPECIFICATIONS − IGNITION IGNITION SS1EY−03 SERVICE DATA Firing order − High−tension cord Resistance Spark plug Recommended spark plug 1−5−3−6−2−4 Maximum 25 kΩ per cord ND NGK Correct electrode gap Ignition coil Primary coil resistance Secondary coil resistance Distributor Crankshaft position sensor Air gap Pickup coil resistance Resistance at cold at hot at cold at hot at cold (G1 − GĜ) (G2 − GĜ) (NE − GĜ) at hot (G1 − GĜ) (G2 − GĜ) (NE − GĜ) at cold (NEę − NEĜ) at hot (NEę − NEĜ) K16R−U BKR5EYA 0.8 mm (0.031 in.) 0.36 − 0.55 Ω 0.45 − 0.65 Ω 9.0 − 15.4 kΩ 11.4 − 18.1 kΩ 0.2 − 0.4 mm (0.008 − 0.016 in.) 185 − 275 Ω 185 − 275 Ω 185 − 275 Ω 240 − 325 Ω 240 − 325 Ω 240 − 325 Ω 1,630 − 2,740 Ω 2,065 − 3,225 Ω 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 140 Brought to you by BirfMark SS−18 SERVICE SPECIFICATIONS − IGNITION SS1EZ−01 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf Spark plug x Cylinder head 20 200 14 Distributor x Cylinder head 18 180 13 Crankshaft position sensor protector x No. 1 oil pan 20 200 14 Crankshaft position sensor x No. 1 oil pan 9 90 78 in.·lbf 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SS−19 SERVICE SPECIFICATIONS − STARTING STARTING SS1F0−04 SERVICE DATA Starter (1.4 kW) Rated voltage and output power No−load characteristics Brush length Spring installed load Commutator Diameter Undercut depth Circle runout Magnetic switch Contact plate for wear Starter (2.0 kW) Rated voltage and output power No−load characteristics Brush length Spring installed load Commutator Diameter Undercut depth Circle runout Magnetic switch Contact plate for wear Current rpm STD Minimum STD Minimum 12 V 1.4 kW 90 A or less at 11.5 V 3,000 rpm or less 15.5 mm (0.610 in.) 10.0 mm (0.394 in.) 17.6 − 23.5 N (1.79 − 2.41 kgf, 4.0 − 5.3 lbf) 11.8 N (1.20 kgf, 2.7 lbf) STD Minimum STD Minimum Maximum 30.0 mm (1.18 in.) 29.0 mm (1.14 in.) 0.6 mm (0.024 in.) 0.2 mm (0.008 in.) 0.05 mm (0.0020 in.) Maximum 0.9 mm (0.035 in.) Current rpm STD Minimum STD Minimum 12 V 2.0 kW 100 A or less at 11.5 V 2,500 rpm or less 15.0 mm (0.591 in.) 9.0 mm (0.354 in.) 21.5 − 27.5 N (2.19 − 2.80 kgf, 4.8 − 6.2 lbf) 12.7 N (1.29 kgf, 2.9 lbf) STD Minimum STD Minimum Maximum 35.0 mm (1.38 in.) 34.0 mm (1.34 in.) 0.7 mm (0.028 in.) 0.2 mm (0.008 in.) 0.05 mm (0.0020 in.) Maximum 0.9 mm (0.035 in.) 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 142 Brought to you by BirfMark SS−20 SERVICE SPECIFICATIONS − STARTING SS1F1−04 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf Starter mounting bolt 39 400 29 Starter wire mounting nut 8.8 90 78 in.·lbf Terminal bolt x Terminal C 17 173 12.5 Terminal bolt x Terminal 30 17 173 12.5 End cover x Magnetic housing 1.4 kW 2.0 kW 2.5 3.6 25 37 22 in.·lbf 32 in.·lbf End cover x Field frame 1.4 kW 2.0 kW 1.5 3.8 15 40 13 in.·lbf 35 in.·lbf Starter hosing x Magnetic switch 1.4 kW 2.0 kW 5.9 9.3 60 95 52 in.·lbf 82 in.·lbf Field frame x Armature assembly 1.4 kW 2.0 kW 5.9 9.3 60 95 52 in.·lbf 82 in.·lbf 5.9 60 52 in.·lbf Lead wire x Terminal C of starter 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SS−21 SERVICE SPECIFICATIONS − CHARGING CHARGING SS1F2−04 SERVICE DATA Battery Voltage at 20°C (68°F) Drive belt Tension New belt Used belt Generator Rated output Rotor coil resistance Slip ring diameter Brush exposed length Voltage regulator Regulating voltage at 20°C (68°F) STD Minimum STD Minimum at 25°C (77°F) at 115°C (239°F) 12.7 − 12.9 400 − 580 N (41.0 − 59.1 kgf, 90.4 − 130.2 lbf) 200 − 390 N (20.4 − 40.0 kgf, 45.0 − 88.2 lbf) 12 V 80 A 2.8 − 3.0 Ω 14.2 − 14.4 mm (0.559 − 0.567 in.) 12.8 mm (0.504 in.) 10.5 mm (0.413 in.) 1.5 mm (0.059 in.) 14.0 − 15.1 V 13.5 − 14.3 V 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 144 Brought to you by BirfMark SS−22 SERVICE SPECIFICATIONS − CHARGING SS1F3−04 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf Bearing retainer x Drive end frame 2.6 27 23 in.·lbf Rectifier end frame x Drive end frame 4.5 46 40 in.·lbf Generator pulley x Rotor 110 1,125 81 Rectifier x Rectifier holder 2.9 30 25 in.·lbf Rear end cover x Rectifier holder 4.4 45 39 in.·lbf Rectifier plate x Rectifier holder 3.8 39 34 in.·lbf Terminal insulator x Rectifier holder 4.1 42 36 in.·lbf Drive belt adjusting bar x Timing chain cover 21 210 15 Generator x Generator bracket 59 600 43 Drive belt adjusting bar x Generator 21 210 15 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SS−23 SERVICE SPECIFICATIONS − AUTOMATIC TRANSMISSION AUTOMATIC TRANSMISSION SS1E6−02 SERVICE DATA Line pressure (Wheel locked) Engine idling AT stall (Throttle valve fully opened) Engine stall revolution Time lag Engine idle speed (A/C OFF) D position R position D position R position D and R position N → D position N → R position N position 422 − 481 kPa (4.3 − 4.9 kgf/cm2, 61 − 70 psi) 510 − 608 kPa (5.2 − 6.2 kgf/cm2, 74 − 88 psi) 1,285 − 1,530 kPa (13.1 − 15.6 kgf/cm2, 128 − 153 psi) 1,579 − 1,932 kPa (16.1 − 19.7 kgf/cm2, 158 − 193 psi) 1,950 ± 150 rpm Less than 1.2 seconds Less than 1.5 seconds 650 ± 50 rpm Throttle cable adjustment (throttle valve fully closed) Between boot and face and inner cable stopper 0 −1 mm (0 − 0.04 in.) Torque converter clutch installation distance Drive plate runout Torque converter clutch runout More than 15.7 mm (0.618 in.) 0.20 mm (0.0079 in.) 0.30 mm (0.0118 in.) Shift point D position Throttle valve fully opened 2 position Throttle valve fully opened L position Throttle valve fully opened Lock−up point D position Max. Max. 1→2 2→3 3 → O/D O/D → 3 3→2 2→1 56 − 62 km/h (35 − 39 mph) 103 − 114 km/h (64 − 71 mph) 152 − 163 km/h (94 − 101 mph) 145 − 156 km/h (90 − 97 mph) 95 − 101 km/h (59 − 63 mph) 42 − 47 km/h (26 − 29 mph) 3→2 116 − 127 km/h (72 − 79 mph) 2→1 56 − 62 km/h (38 − 39 mph) Throttle valve opening 5 % Lock−up ON Lock−up OFF 77 − 83 km/h (48 − 52 mph) 68 − 74 km/h (42 − 46 mph) 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 146 Brought to you by BirfMark SS−24 SERVICE SPECIFICATIONS − AUTOMATIC TRANSMISSION SS1E7−01 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf Valve body x Transmission case 10 100 7 Oil stainer x Valve body 10 100 7 Oil pan 7.4 75 65 in.·lbf Drain plug x Oil pan 20 205 15 Parking lock pawl bracket x Transmission case 7.4 75 65 in.·lbf Front propeller shaft x Front differential 74 750 54 Front propeller shaft x Transfer 74 750 54 Rear propeller shaft x Transfer 88 900 65 Rear propeller shaft x Rear differential 88 900 65 Drive plate x Crankshaft 98 1,000 72 Torque converter clutch x Drive plate 55 550 40 Front exhaust pipe x Exhaust manifold 62 630 46 Front exhaust pipe x TWC 39 400 29 Oil cooler pipe 34 350 25 Transmission x Engine 71 730 53 Exhaust pipe clamp 19 195 14 6.9 13 70 130 61 in.·lbf 9 No. 2 vehicle speed sensor 5.4 55 48 in.·lbf Speedometer driven gear sleeve x Locking plate 16 160 12 Starter mounting bolt 39 400 29 Transfer shift lever 18 185 13 Stabilizer bar bracket mounting bolt 18 185 13 Engine under cover mounting bolt 28 290 21 Exhaust pipe No. 1 support bracket x Torque converter clutch housing 24 240 17 Crossmember x Frame 61 620 45 Engine rear mounting x Crossmember 74 750 54 Transmission shift lever assembly x Body 5.4 55 48 in.·lbf Oil cooler mounting bolt 11 115 8 Park/neutral position switch Nut Bolt 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SS−25 SERVICE SPECIFICATIONS − TRANSFER TRANSFER SS1E8−02 SERVICE DATA Idler gear rear bearing adjusting shim thickness Mark 2 3 4 5 6 7 8 9 10 11 12 13 0.30 mm (0.0118 in.) 0.45 mm (0.0177 in.) 2.40 mm (0.0945 in.) 2.60 mm (0.1024 in.) 2.80 mm (0.1102 in.) 3.00 mm (0.1181 in.) 3.20 mm (0.1260 in.) 3.40 mm (0.1339 in.) 3.60 mm (0.1417 in.) 3.80 mm (0.1496 in.) 4.00 mm (0.1575 in.) 0.55 mm (0.0216 in.) Output shaft rear bearing adjusting shim thickness Mark B C D E F G H J K L M N 0.30 mm (0.0118 in.) 0.45 mm (0.0177 in.) 1.00 mm (0.0394 in.) 1.20 mm (0.0472 in.) 1.40 mm (0.0551 in.) 1.60 mm (0.0630 in.) 1.80 mm (0.0709 in.) 2.00 mm (0.0787 in.) 2.20 mm (0.0866 in.) 2.40 mm (0.0945 in.) 2.60 mm (0.1024 in.) 0.55 mm (0.0216 in.) Input gear snap ring thickness Mark A B C D E F G H J 2.00 mm (0.0787 in.) 2.10 mm (0.0827 in.) 2.20 mm (0.0866 in.) 2.30 mm (0.0906 in.) 2.40 mm (0.0945 in.) 2.50 mm (0.0984 in.) 2.60 mm (0.1024 in.) 2.70 mm (0.1063 in.) 2.80 mm (0.1102 in.) Input shaft rear ball bearing snap ring thickness Mark A B C D E 2.00 mm (0.0787 in.) 2.10 mm (0.0827 in.) 2.20 mm (0.0866 in.) 2.30 mm (0.0906 in.) 2.40 mm (0.0945 in.) Idler low gear thrust clearance STD Max. 0.125 − 0.275 mm (0.0049 − 0.0108 in.) 0.275 mm (0.0108 in.) Idler low gear radial clearance STD Max. 0.015 − 0.068 mm (0.0006 − 0.0027 in.) 0.068 mm (0.0027 in.) High speed output gear thrust clearance STD Max. 0.10 − 0.25 mm (0.0039 − 0.0098 in.) 0.25 mm (0.0098 in.) High speed output gear radial clearance STD Max. 0.015 − 0.071 mm (0.0006 − 0.0028 in.) 0.071 mm (0.0028 in.) Center differential backlash Min. 0.05 mm (0.0020 in.) 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 148 Brought to you by BirfMark SS−26 SERVICE SPECIFICATIONS − TRANSFER Center differential side gear thrust washer thickness 1.70 mm (0.0669 in.) 1.85 mm (0.0728 in.) 2.00 mm (0.0787 in.) 2.15 mm (0.0846 in.) 2.30 mm (0.0906 in.) 2.45 mm (0.0965 in.) 2.60 mm (0.1024 in.) 2.75 mm (0.1083 in.) 2.90 mm (0.1142 in.) 3.05 mm (0.1201 in.) Front drive gear piece snap ring thickness Mark A B C D E F G H J K L 2.00 mm (0.0787 in.) 2.10 mm (0.0827 in.) 2.20 mm (0.0866 in.) 2.30 mm (0.0906 in.) 2.40 mm (0.0945 in.) 2.50 mm (0.0984 in.) 2.60 mm (0.1024 in.) 2.70 mm (0.1063 in.) 2.80 mm (0.1102 in.) 1.80 mm (0.0709 in.) 1.90 mm (0.0748 in.) Front extension housing ball bearing snap ring thickness Mark A B 1.7 mm (0.0669 in.) 1.8 mm (0.0709 in.) Front output shaft hub snap ring thickness Mark A B C D E 1.8 mm (0.0709 in.) 1.9 mm (0.0748 in.) 2.0 mm (0.0787 in.) 2.1 mm (0.0827 in.) 2.2 mm (0.0866 in.) Oil pump driven rotor body clearance STD Max. 0.08 − 0.17 mm (0.0031 − 0.0067 in.) 0.17 mm (0.0067 in.) Oil pump driven rotor body tip clearance STD Max. 0.05 − 0.15 mm (0.0020 − 0.0059 in.) 0.15 mm (0.0059 in.) Oil pump side clearance STD Max. 0.03 − 0.10 mm (0.0012 − 0.0039 in.) 0.10 mm (0.0039 in.) Rear extension housing ball bearing snap ring thickness Mark A B 1.7 mm (0.0669 in.) 1.8 mm (0.0709 in.) Rear output shaft ball bearing snap ring thickness Mark 1 2 3 4 1.95 mm (0.0768 in.) 2.05 mm (0.0807 in.) 2.15 mm (0.0847 in.) 2.25 mm (0.0886 in.) Motor actuator Terminal 2 − Terminal 3 Terminal 2 or 3 − Body ground STD resistance STD resistance 0.3 − 100 Ω More than 0.5 MΩ 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 149 Brought to you by BirfMark SS−27 SERVICE SPECIFICATIONS − TRANSFER SS1E9−02 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf Oil pump plate and separator x Rear extension housing 4.9 50 43 in.·lbf Oil pump cover x Rear extension housing 4.9 50 43 in.·lbf Lever lock pin 12 120 9 Oil strainer x Rear case 4.9 50 43 in.·lbf Oil receiver x Front case 12 120 9 Case cover x Rear case 37 380 27 Rear extension housing x Rear case 37 380 27 Front extension housing x Front case 37 380 27 Center differential lock Indicator switch 37 380 14 L4 position switch 37 380 27 Neutral position switch 37 380 27 Screw plug x Front case 19 190 14 Screw plug x Rear extension housing 29 300 22 Motor actuator x Front case 18 185 13 98 88 1,000 900 72 65 Front case x Rear case 37 380 27 Rear case x Retainer 39 400 28 Dynamic damper x Rear extension housing 37 380 27 Differential front case x Differential rear case Temporarily tighten 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SS−28 SERVICE SPECIFICATIONS − PROPELLER SHAFT PROPELLER SHAFT SS1EA−02 SERVICE DATA Propeller shaft runout Max. Spider bearing axial play Snap ring thickness Font propeller shaft and rear propeller shaft (Type B) Rear propeller shaft (Type A) 0.8 mm (0.031 in.) Less than 0.05 mm (0.0020 in.) Mark Color 1 − 2 − 3 − − Brown − Blue 6 − 7 − 8 − Color − Brown Blue − 2.100 − 2.150 mm (0.0827 − 0.0846 in.) 2.150 − 2.200 mm (0.0846 − 0.0866 in.) 2.200 − 2.250 mm (0.0866 − 0.0886 in.) 2.250 − 2.300 mm (0.0886 − 0.0906 in.) 2.300 − 2.350 mm (0.0906 − 0.0925 in.) 2.350 − 2.400 mm (0.0925 − 0.0945 in.) 2.400 − 2.450 mm (0.0945 − 0.0965 in.) 2.450 − 2.500 mm (0.0965 − 0.0984 in.) 2.00 mm (0.0787 in.) 2.03 mm (0.0799 in.) 2.06 mm (0.0811 in.) 2.09 mm (0.0823 in.) 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 151 Brought to you by BirfMark SS−29 SERVICE SPECIFICATIONS − PROPELLER SHAFT SS1EB−01 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf Front propeller shaft x Front differential 74 750 54 Front propeller shaft x Transfer 74 750 54 Rear propeller shaft x Rear differential 88 900 65 Rear propeller shaft x Transfer 88 900 65 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SS−30 SERVICE SPECIFICATIONS − SUSPENSION AND AXLE SUSPENSION AND AXLE SS1EC−02 SERVICE DATA Cold tire inflation pressure Tire size P275/70R 16 220 kPa (2.2 kgf/cm2, 32 psi) Follow spring and bumper stopper clearance Follow spring clearance (Front) Bumper stopper clearance (Rear) 36 mm (1.42 in.) 104 mm (4.09 in.) Front wheel alignment Camber Left−right error 1°00’ ± 45’ 45’ or less Left−right error 3°00’ ± 60’ 45’ or less Caster Steering axis inclination Toe−in (Total) 13°00’ ± 45’ Inspection STD Adjustment STD Wheel angle (Max.) Inside wheel Outside wheel Tire and wheel Tire runout Wheel balance (Unbalance after adjustment) Wheel bearing preload (at starting) (Rotating load at hub bolt) Front axle Steering knuckle bearing preload (Rotating load at knuckle end, before installing dust seal) Front differential Drive pinion preload (at starting) 0.2° ± 0.2° (2 ± 2 mm, 0.08 ± 0.08 in.) 0.2° ± 0.1° (2 ± 1 mm, 0.08 ± 0.04 in.) 32°00’ − 35°00’ 31°00’ 3.0 mm (0.118 in.) or less 13.0 g (0.029 lb) or less Front 28 − 56 N (2.9 − 5.7 kgf, 6.4 − 12.6 lbf) Rear 26 − 57 N (2.6 − 5.8 kgf, 5.7 − 12.8 lbf) New bearing Reused bearing 25 − 44 N (2.5 − 4.5 kgf, 5.5 − 9.9 lbf) 0.9 − 1.6 N·m (10 − 16 kgf·cm, 8.7 − 13.9 in.·lbf) 0.5 − 0.8 N·m (5 − 8 kgf·cm, 4.3 − 6.9 in.·lbf) Total preload (at starting) Drive pinion preload plus 0.4 − 0.6 N·m (4 − 6 kgf·cm, 3.5 − 5.2 in.·lbf) Drive pinion to ring gear backlash 0.13 − 0.18 mm (0.0051 − 0.0071 in.) Pinion gear to side gear backlash 0.05 − 0.20 mm (0.0020 − 0.0079 in.) Ring gear runout Companion flange runout Max. Max. Radial 0.10 mm (0.0039 in.) Lateral 0.10 mm (0.0039 in.) Oil seal drive in depth Side gear thrust washer thickness 0.10 mm (0.0039 in.) 1.0 mm (0.039 in.) w/o Differntial lock w/ Differntial lock 1.6 mm (0.063 in.) 1.7 mm (0.067 in.) 1.8 mm (0.071 in.) 0.9 mm (0.035 in.) 1.0 mm (0.039 in.) 1.1 mm (0.043 in.) 1.2 mm (0.047 in.) 1.3 mm (0.051 in.) 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 153 Brought to you by BirfMark SS−31 SERVICE SPECIFICATIONS − SUSPENSION AND AXLE Front differential (cont’d) Drive pinion adjusting plate washer thickness 1.70 mm (0.0669 in.) 1.73 mm (0.0681 in.) 1.76 mm (0.0693 in.) 1.79 mm (0.0705 in.) 1.82 mm (0.0717 in.) 1.85 mm (0.0728 in.) 1.88 mm (0.0740 in.) 1.91 mm (0.0752 in.) 1.94 mm (0.0764 in.) 1.97 mm (0.0776 in.) 2.00 mm (0.0787 in.) 2.03 mm (0.0799 in.) 2.06 mm (0.0811 in.) 2.09 mm (0.0823 in.) 2.12 mm (0.0835 in.) 2.15 mm (0.0846 in.) 2.18 mm (0.0858 in.) 2.21 mm (0.0870 in.) 2.24 mm (0.0882 in.) 2.27 mm (0.0894 in.) 2.30 mm (0.0906 in.) 2.33 mm (0.0917 in.) Rear differential Drive pinion preload (at starting) 1.3 − 2.0 N·m (13 − 20 kgf·cm, 11.3 − 17.4 in.·lbf) 0.7 − 1.0 N·m (7 − 10 kgf·cm, 6.1 − 8.7 in.·lbf) New bearing Reused bearing Total preload (at starting) w/o Differntial lock w/ Differntial lock Drive pinion preload plus 0.4 − 0.6 N·m (4 − 6 kgf·cm, 3.5 − 5.2 in.·lbf) 0.3 − 0.7 N·m (3 − 7 kgf·cm, 2.6 − 6.1 in.·lbf) Drive pinion to ring gear backlash 0.15 − 0.20 mm (0.0059 − 0.0079 in.) Pinion gear to side gear backlash 0.02 − 0.20 mm (0.0008 − 0.0079 in.) Ring gear runout Max. Companion flange runout 0.10 mm (0.0039 in.) Max. Radial 0.10 mm (0.0039 in.) Lateral 0.10 mm (0.0039 in.) Oil seal drive in depth 1.0 mm (0.039 in.) Side gear thrust washer thickness 1.60 mm (0.0630 in.) 1.75 mm (0.0689 in.) 1.90 mm (0.0748 in.) 2.05 mm (0.0807 in.) Drive pinion adjusting plate washer thickness 1.05 mm (0.0413 in.) 1.10 mm (0.0433 in.) 1.15 mm (0.0453 in.) 1.20 mm (0.0472 in.) 1.25 mm (0.0492 in.) 1.30 mm (0.0512 in.) 1.35 mm (0.0531 in.) 1.40 mm (0.0551 in.) 1.45 mm (0.0571 in.) 1.50 mm (0.0591 in.) 1.55 mm (0.0610 in.) 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 154 Brought to you by BirfMark SS−32 SERVICE SPECIFICATIONS − SUSPENSION AND AXLE Rear differential (cont’d) Side bearing adjusting plate thickness (w/ Differential lock only) 2.67 mm (0.1051 in.) 2.70 mm (0.1063 in.) 2.73 mm (0.1075 in.) 2.76 mm (0.1087 in.) 2.79 mm (0.1098 in.) 2.82 mm (0.1110 in.) 2.85 mm (0.1122 in.) 2.88 mm (0.1134 in.) 2.91 mm (0.1146 in.) 2.94 mm (0.1157 in.) 2.97 mm (0.1169 in.) 3.00 mm (0.1181 in.) 3.03 mm (0.1193 in.) 3.06 mm (0.1205 in.) 3.09 mm (0.1217 in.) 3.12 mm (0.1228 in.) 3.15 mm (0.1240 in.) 3.18 mm (0.1252 in.) 3.21 mm (0.1264 in.) 3.24 mm (0.1276 in.) 3.27 mm (0.1287 in.) 3.30 mm (0.1299 in.) 3.33 mm (0.1311 in.) Rear axle Rear axle shaft runout Max. Distance between top surface of axle housing and lock nut 0.8 mm (0.031 in.) −0.2 − 0.9 mm (−0.0079 − 0.0354 in.) 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 155 Brought to you by BirfMark SS−33 SERVICE SPECIFICATIONS − SUSPENSION AND AXLE SS1ED−02 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf Axle hub x Disc 64 650 47 Axle hub bearing lock nut 64 650 47 Flange x Axle hub 35 360 26 Brake caliper x Axle carrier 123 1,250 90 Brake caliper x Flexible hose 30 310 22 Steering knuckle x Knuckle arm 96 980 71 Bearing cap x Steering knuckle 96 980 71 Knuckle arm x Tie rod 91 925 67 Steering knuckle x Knuckle spindle 47 475 34 Oil seal end retainer x Knuckle arm 5.4 55 48 in.·lbf ABS speed sensor set bolt x Steering knuckle 18 185 13 147 103 1,500 1,050 109 76 Drain plug 49 500 36 Filler plug 49 500 36 Propeller shaft x Companion flange 88 900 65 Side bearing cap x Differential carrier 78 800 58 Ring gear x Differential case 97 985 71 196 − 343 2,000 − 3,500 145 − 253 Differential LH case x RH case 47 480 35 Differential lock shift retainer 24 240 17 Differential lock screw plug 22 220 16 Differential lock indicator switch 40 410 30 Differential lock actuator 26 270 20 Differential carrier x Axle housing 27 280 20 Adjusting nut lock x Bearing cap 13 130 9 Follow spring x Frame 9.2 94 82 in.·lbf Stabilizer bar x Axle housing 25 260 19 Shock absorber x Axle housing 69 700 51 Shock absorber x Frame 69 700 51 Stabilizer bar link x Cover 18 185 13 Stabilizer bar link x Link bracket 103 1,050 76 Lateral control rod x Frame 171 1,750 127 Lateral control rod x Axle housing 171 1,750 127 Leading arm x Frame 177 1,800 130 Leading arm x Axle housing 171 1,750 127 Rear axle shaft x Axle hub 34 340 25 Rear axle bearing lock nut 59 600 43 Rear axle bearing lock nut screw 5.4 55 48 in.·lbf Brke caliper x Axle carrier 103 1,050 76 ABS speed sensor set bolt 18 185 13 FRONT Hub nut Drive pinion x Companion flange Steel wheel Aluminum wheel REAR 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SS−34 SERVICE SPECIFICATIONS Hub nut − SUSPENSION AND AXLE 147 103 1,500 1,050 109 76 Drain plug 49 500 36 Filler plug 49 500 36 27 58 275 590 20 43 74 750 54 78 113 800 1,150 58 83 Ring gear x Differential case 110 1,125 81 Companion flange x Drive pinion (Maximum torque) 441 4,500 325 Differential carrier x Axle housing 73 740 54 Adjusting nut lock x Bearing cap 13 130 9 Differential case x Differential cover 58 590 43 Differential lock shift fork set bolt 20 200 14 Differential lock actuator 24 240 17 Differential lock cover 18 185 13 Differential lock indicator switch 40 410 30 35 20 360 200 26 14 Follow spring x Frame 28 290 21 Shock absorber x Bracket 69 700 51 Shock absorber bracket x Frame 50 510 37 Shock absorber x Axle housing 64 650 47 Lateral control rod x Frame 177 1,800 130 Lateral control rod x Axle housing 245 2,500 181 Upper control rod x Frame 177 1,800 130 Upper control rod x Axle housing 177 1,800 130 Lower control arm x Frame 177 1,800 130 Lower control arm x Axle housing 177 1,800 130 Stabilizer bar x Link 25 260 19 Stabilizer bar link x Link bracket 103 1,050 76 Cover x Axle housing 18 185 13 Pinion shaft pin Steel wheel Aluminum wheel w/o Differential lock w/ Differential lock Propeller shaft x Companion flange Side bearing cap x Differential carrier Actuator protector w/o Differential lock w/ Differential lock Nut Bolt 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SS−35 SERVICE SPECIFICATIONS − BRAKE BRAKE SS1EE−02 SERVICE DATA Brake pedal height from asphalt sheet 167.5 − 177.5 mm (6.59 − 6.99 in.) Brake pedal freeplay 3 − 6 mm (0.12 − 0.24 in.) Brake pedal reserve distance at 490 N (50 kgf, 110.2 lbf) More than 68 mm (2.68 in.) Brake booster push rod to piston clearance w/ SST 0 mm (0 in.) Front brake pad thickness STD 9.5 mm (0.374 in.) Minimum 1.0 mm (0.039 in.) Front brake disc thickness STD 32.0 mm (1.260 in.) Minimum 30.0 mm (1.181 in.) Front brake disc runout Maximum 0.15 mm (0.0059 in.) Rear brake pad thickness STD 10.0 mm (0.394 in.) Minimum 1.0 mm (0.039 in.) Rear brake disc thickness STD 18.0 mm (0.709 in.) Minimum 16.0 mm (0.630 in.) Rear brake disc runout Maximum 0.15 mm (0.0059 in.) Rear brake disc inside diameter STD 230 mm (9.06 in.) Maximum 231 mm (9.09 in.) Parking brake shoe lining thickness STD 4.0 mm (0.157 in.) Minimum 1.0 mm (0.039 in.) Parking brake lever travel at 196 N (20 kgf, 44.1 lbf) 7 − 9 clicks Parking brake clearance between rear shoe and lever Less than 0.35 mm (0.0138 in.) Parking brake shoe and lever clearance adjusting shim thickness 0.3 mm (0.012 in.) 0.6 mm (0.024 in.) 0.9 mm (0.035 in.) 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 158 Brought to you by BirfMark SS−36 SERVICE SPECIFICATIONS − BRAKE SS1EF−02 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf Master cylinder x Piston stopper bolt 10 100 7 Master cylinder x Reservoir 1.7 17.5 15.2 in.·lbf Master cylinder x Brake booster 13 130 9 Brake line union nut 15 155 11 Brake booster clevis lock nut 25 260 19 Brake booster x Pedal bracket 13 130 9 Bleeder plug 11 110 8 Front disc brake caliper installation bolt 123 1,250 90 Front disc brake caliper x Flexible hose 30 310 22 Parking brake bellcrank x Backing plate 13 130 9 Rear disc brake cliper x Spindle pin 88 900 65 Rear disc brake caliper x Flexible hose 30 310 22 Rear disc brake torque plate x Knuckle 103 1,050 76 LSP & BV bracket x Frame 25 260 19 LSP & BV x LSP & BV bracket 13 130 9 LSP & BV spring x LSP & BV bracket 18 185 13 LSP & BV spring x Shackle No. 1 18 185 13 LSP & BV shackle lock nut 25 250 18 LSP & BV shackle x Shackle bracket 13 130 9 LSP & BV shackle bracket x Rear axle housing 19 195 14 ABS actuator assembly x Body 19 195 14 ABS actuator x Actuator bracket 5.4 55 48 in.·lbf ABS control relay x Actuator bracket 13 130 9 Front speed sensor installation bolt 18 185 13 Rear speed sensor installation bolt 18 185 13 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SS−37 SERVICE SPECIFICATIONS − STEERING STEERING SS1EG−02 SERVICE DATA ON−VEHICLE INSPECTION Steering wheel freeplay Maximum 40 mm (1.57 in.) Fluid level rise Maximum Below 5 mm (020 in.) Fluid pressure at idle speed with valve closed Steering effort at idle speed Minimum 9,316 kPa (95 kgf/cm2, 1,351 psi) Maximum 8.3 N·m (85 kgf·cm, 73 in.·lbf) TILT STEERING COLUMN Pawl stopper alignment mark 1 or A 2 or B 3 or C 4 or D 5 or E 12.65 − 12.75 mm (0.4980 − 0.5020 in.) 12.55 − 12.65 mm (0.4941 − 0.4980 in.) 12.45 − 12.55 mm (0.4902 − 0.4941 in.) 12.35 − 12.45 mm (0.4962 − 0.4902 in.) 12.25 − 12.35 mm (0.4823 − 0.4862 in.) PS VANE PUMP Oil clearance between pump shaft and bushing STD 0.03 − 0.05 mm (0.0012 − 0.0020 in.) Maximum 0.07 mm (0.0028 in.) Vane plate height Minimum 8.6 mm (0.339 in.) Vane plate thickness Minimum 1.397 mm (0.05500 in.) Vane plate length Minimum 14.991 mm (0.59016 in.) Vane plate and pump rotor groove clearance Vane plate length Spring free length Vane pump rotaing torque Maximum 0.033 mm (0.00130 in.) Pump rotor mark None 1 2 Cam ring mark 2 3 4 STD 14.995 − 14.997 mm (0.59035 − 0.59043 in.) 14.993 − 14.995 mm (0.59027 − 0.59035 in.) 14.991 − 14.993 mm (0.59020 − 0.59027 in.) 14.995 − 14.997 mm (0.59035 − 0.59043 in.) 14.993 − 14.995 mm (0.59027 − 0.59035 in.) 14.991 − 14.993 mm (0.59020 − 0.59027 in.) 35 − 37 mm (1.38 − 1.46 in.) Maximum 0.3 N·m (2.8 kgf·cm, 2.4 in.·lbf) PS GEAR Worm gear valve body ball clearance Cross shaft adjusting screw thrust clearance Maximum 0.15 mm (0.059 in.) STD 0.03 − 0.05 mm (0.0012 − 0.0020 in.) Worm gear preload 0.3 − 0.5 N·m (3 − 5.5 kgf·cm, 2.6 − 4.8 in.·lbf) Total preload 0.74 − 1.08 N·m (7.5 − 11.0 kgf·cm, 6.5 − 9.6 in.·lbf) STEERING LINKAGE Tie rod length Approximately 1.207 mm (47.51 in.) Relay rod length Approximately 1.085 mm (42.72 in.) 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 160 Brought to you by BirfMark SS−38 SERVICE SPECIFICATIONS − STEERING SS1EH−02 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf Steering wheel set nut 34 350 25 Steering wheel pad set screw (Torx screw) 9.0 90 78 in.·lbf Steering column assembly set nut and bolt 25 250 18 Sliding yoke sub−assembly x Worm gear valve body shaft 34 350 25 Sliding yoke sub−assembly x Intermediate No. 2 shaft 34 350 25 Universal joint x Intermediate No. 2 shaft 34 350 25 Main shaft assembly x Universal joint 34 350 25 Turn signal bracket set bolt 4.9 50 43 in.·lbf TILT STEERING COLUMN Tilt sub lever side pawl set bolt x Nut 5.9 60 52 in.·lbf Tilt lever retainer set nut 15 150 11 Tilt lever assembly set bolt 2.9 30 26 in.·lbf Compression spring set bolt 7.8 80 69 in.·lbf Column hole cover x Lower dust seal 5.9 60 52 in.·lbf Column hole cover x Body 13 130 9 Link joint protector set bolt 12 120 9 Pressure feed tube set union bolt 56 575 42 PS VANE PUMP PS vane pump assembly set nut 36 370 27 Suction port union set bolt 13 130 9 Vane pump drive gear set nut 74 750 54 Pressure port union 69 700 51 PS GEAR Pressure tube x Gear housing assembly for use with SST for use without SST 36 44 365 450 26 33 Return tube x Gear housing assembly for use with SST for use without SST 36 44 365 450 26 33 Gear housing assembly x Body 142 1,450 105 Pitman arm x Cross shaft 177 1,800 130 Cross shaft adjusting screw set nut 46 470 34 Side cover x Gear housing 61 620 45 Plunger guide nut 20 205 15 Worm gear valve body assembly x Gear housing 61 620 45 Control valve shaft x Sliding york sub−assembly 34 350 25 Pitman arm x Cross shaft 177 1,800 130 Pitman arm x Relay rod 91 925 67 Tie rod clamp bolt 37 375 27 Tie rod x Knuckle arm 91 925 67 STEERING LINKAGE Relay rod x Steering damper 74 750 54 Steering damper x Steering damper bracket 74 750 54 Steering damper bracket x Body 74 750 54 Relay rod clamp bolt 37 375 27 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark SS−39 SERVICE SPECIFICATIONS − SUPPLEMENTAL RESTRAINT SYSTEM SUPPLEMENTAL RESTRAINT SYSTEM SS1EI−01 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf Steering wheel set nut 34 350 25 Steering wheel pad 9.0 90 80 in.·lbf Front passenger airbag assembly x Instrument panel reinforcement 20 205 15 Airbag sensor assembly 20 205 15 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 162 Brought to you by BirfMark SS−40 SERVICE SPECIFICATIONS − BODY ELECTRICAL BODY ELECTRICAL SS1EJ−02 SERVICE DATA TURN SIGNAL FLASHER Flashes/Minute 60 − 120 SPEEDOMETER (USING A SPEEDOMETER) Standard indication (mph) Allowable range (mph) 20 18 − 24 40 38 − 44 60 58 − 66 80 78 − 88 100 98 − 110 120 118 − 132 TACHOMETER (ON−VEHICLE) DC 13.5 V 25°C (77°F) Standard indication (RPM) Allowable range (RPM) 700 630 − 770 1,000 900 − 1,100 2,000 1,875 − 2,125 3,000 2,850 − 3,150 4,000 3,850 − 4,150 5,000 4,850 − 5,150 A−B 85.5 −105.5 Ω A−C 126 − 150 Ω B−C 90 − 110 Ω Float position F: Approx. 15 mm ((0.59 in.) Approx. 3 Ω Float position E: Approx. 200 (7.87 in.) Approx. 110 Ω FUEL RECEIVER GAUGE FUEL SENDER GAUGE ENGINE COOLANT TEMPERATURE RECEIVER GAUGE A−B 71 − 79 Ω A−C 117 − 141 Ω B−C 185 − 215 Ω OIL PRESSURE RECEIVER GAUGE Resistance 40 − 48 Ω CRUISE CONTROL SWITCH Switch position OFF No continuity Switch position RESUME/ACCEL Approx. 68 Ω Switch position SET/COAST Approx. 198 Ω Switch position CANCEL Approx. 418 Ω CRUISE CONTROL ACTUATOR 1−3 Approx. 2 kΩ 2−3 Approx. 0.5 − 1.7 kΩ Actuator control arm free play 0 mm (0 in.) 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 163 Brought to you by BirfMark SS−41 SERVICE SPECIFICATIONS − BODY BODY SS1EK−02 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf 39 400 29 Front bumper arm x Body 39 400 29 Front bumper extension x Front bumper 5.4 55 48 in.·lbf Rear bumper extension x Rear bumper reinforcement 13 130 9 Rear bumper extension reinforcement x Body 5.4 55 48 in.·lbf Hood hinge x Body 18 185 13 Hood lock x Body 8 80 69 in.·lbf FRONT BUMPER Front bumper arm x Front bumper bracket REAR BUMPER HOOD FRONT DOOR Door hinge x Body 24 240 17 Door hinge x Door panel 24 240 17 Door lock x Door panel 5 50 43 in.·lbf Window regulator x Door panel 5 50 43 in.·lbf Door hinge x Body 24 240 17 Door hinge x Door panel 24 240 17 Door lock x Door panel 5 50 43 in.·lbf Window regulator x Door panel 5 50 43 in.·lbf Front wiper arm x Wiper link 20 210 15 Wiper link x Body 5.4 55 48 in.·lbf Wiper motor x Body 5.4 55 48 in.·lbf Rear wiper arm x Wiper motor 5.4 55 48 in.·lbf Front wheel opening extension x Body 5.4 55 48 in.·lbf Rear wheel opening extension x Body 5.4 55 48 in.·lbf 20 210 15 Seat truck x Body 39 400 29 Seat reclining assembly x Seatback frame 52 530 38 Lumber support x Seatback frame 18 185 13 Seat truck x Body 39 400 29 Power seat adjuster x Seatback frame 37 375 27 Power seat adjuster x Seatback cushion frame 18 185 13 Lumber support x Seatback frame 18 185 13 Seat cushion hinge x Body 39 400 29 Seat cushion hinge x Seat cushion frame 39 400 29 REAR DOOR WIPER AND WASHER WHEEL OPENING EXTENSION INSTRUMENT PANEL Front passenger airbag assembly x Instrument panel reinforcement FRONT MANUAL SEAT FRONT POWER SEAT NO. 1 REAR SEAT 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 164 Brought to you by BirfMark SS−42 SERVICE SPECIFICATIONS − BODY Seat lock x Seat cushion frame 41 420 30 Reclining adjuster x Seatback frame 52 530 38 Seat leg x Body 18 185 13 10 2 100 20 7 17 in.·lbf No. 1 vertical seat link x Front vertical motor 10 100 7 Seat truck x Seat truck inner reinforcement 20 210 15 Front seat horizontal seat screw x Front seat motor slide housing 19 200 14 10 2 100 20 7 17 in.·lbf 19 200 14 Adjustable anchor x Body 43 440 32 ELR x Body 5 50 43 in.·lbf Outer belt anchor x Body 43 440 32 Inner belt x Seat 43 440 32 Side step bracket x Body 13 130 9 Side step bracket x Side panel 5.4 55 48 in.·lbf NO. 2 REAR SEAT POWER SEAT ADJUSTER No. 2 vertical seat link x Rear vertical motor Slide motor x Front seat horizontal jack screw Front seat horizontal jack screw x Front seat truck Bolt Nut Bolt Nut SEAT BELT SIDE STEP 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 165 Brought to you by BirfMark SS−43 SERVICE SPECIFICATIONS − AIR CONDITIONING AIR CONDITIONING SS1EL−01 SERVICE DATA Refrigerant charge volume Drive belt tension 850 ± 50 g (59.98 ± 1.76 oz.) New belt Used belt 100 − 150 lbf 60 − 100 lbf Idle−up speed 800 rpm Magnetic clutch clearance 0.5 ± 0.15 mm (0.020 ± 0.0059 in.) 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 166 Brought to you by BirfMark SS−44 SERVICE SPECIFICATIONS − AIR CONDITIONING SS1EM−02 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf Compressor x Suction hose 10 100 7 Compressor x Discharge hose 10 100 7 Condensser x Compressor bracket 25 250 18 Compressor bracket x Engine 37 375 27 Receiver x Liquid tube 5.4 55 48 in.·lbf Condenser x Discharge hose 10 100 7 Cooling unit x Liqied tube 10 100 7 Cooling unit x Suction tube 10 100 7 Pressure switch x Liquid tube 10 100 7 Expansion valve x Evaporetor 5.4 55 48 in.·lbf Liquid line (Union nut) 14 140 10 Suction line (bolt) 10 140 7 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark ST−1 STARTING − STARTING SYSTEM STARTING SYSTEM ST08A−02 ON−VEHICLE INSPECTION NOTICE: Before changing the starter, check these items again: S Connector connection S Accessory installation, e.g.: theft deterrent system 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 749 Brought to you by BirfMark ST−2 STARTING − STARTER STARTER ST0KO−01 COMPONENTS 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 750 Brought to you by BirfMark ST−3 STARTING − STARTER 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 751 Brought to you by BirfMark ST−4 STARTING − STARTER REMOVAL REMOVE STARTER (a) Disconnect the starter connector. (b) Remove the nut, and disconnect the starter wire. Torque: 8.8 N·m (90 kgf·cm, 70 in.·lbf) (c) Remove the 2 bolts and starter. Torque: 39 N·m (400 kgf·cm, 29 ft·lbf) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 ST0KP−01 Brought to you by BirfMark ST−5 STARTING − STARTER DISASSEMBLY ST0KQ−01 HINT: At the time of reassembly, use high−temperature grease to lubricate the bearings, gears, return spring and steel ball when assembling the starter. 1. (a) REMOVE FIELD FRAME AND ARMATURE Remove the nut, and disconnect the lead wire from the magnetic switch terminal. Torque: 5.9 N·m (60 kgf·cm, 52 in.·lbf) (b) Remove the 2 through bolts. Torque: 1.4 kW type: 5.9 N·m (60 kgf·cm, 52 in.·lbf) 2.0 kW type: 9.3 N·m (95 kgf·cm, 82 in.·lbf) Pull out the field frame with the armature from the magnetic switch assembly. Remove the O−ring. P23005 (c) P23006 (d) HINT: At the time of reassembly, use a new O−ring. HINT: At the time of reassembly, align the protrusion of the field frame with cutout of the magnetic switch. P08385 2. (a) REMOVE STARTER HOUSING, CLUTCH ASSEMBLY AND GEAR Remove the 2 screws. Torque: 1.4 kW type: 5.9 N·m (60 kgf·cm, 52 in.·lbf) 2.0 kW type: 9.3 N·m (95 kgf·cm, 82 in.·lbf) P23007 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark ST−6 STARTING (4) (1) (5) (b) (3) − STARTER Remove these parts from the magnetic switch assembly: (1) Starter housing (2) Return spring (3) Bearing (4) Idler gear (5) Starter clutch assembly (2) P04683 3. REMOVE STEEL BALL Using a magnetic finger, remove the steel ball from the clutch shaft hole. Magnetic Finger P04515 4. (a) P23004 REMOVE BRUSH HOLDER Remove the 2 screws, 2 O−rings and end cover from the field frame. Torque: 1.4 kW type: 1.5 N·m (15 kgf·cm, 13 in.·lbf) 2.0 kW type: 3.8 N·m (40 kgf·cm, 35 in.·lbf) HINT: At the time of reassembly, use new O−rings. (b) Remove the O−ring from the field frame. HINT: At the time of reassembly, use a new O−ring. (c) 5. Using a screwdriver, hold the spring back and disconnect the brush from the brush holder. Disconnect the four brushes and remove the brush holder. REMOVE ARMATURE FROM FIELD FRAME P04525 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark ST−7 STARTING − STARTER INSPECTION Ohmmeter ST0N8−01 1. INSPECT COMMUTATOR FOR OPEN CIRCUIT Using an ohmmeter, check that there is continuity between the segments of the commutator. If there is no continuity between any segment, replace the armature. Continuity P10584 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. 3. INSPECT COMMUTATOR FOR DIRTY AND BURNT SURFACES If the surface is dirty or burnt, correct it with sandpaper (No. 400) or on a lathe. Ohmmeter No Continuity P10585 4. (a) (b) INSPECT COMMUTATOR CIRCLE RUNOUT Place the commutator on V−blocks. Using a dial gauge, measure the circle runout. Maximum circle runout: 0.05 mm (0.0020 in.) If the circle runout is greater than maximum, correct it on a lathe. P10586 P10587 ST0040 5. INSPECT COMMUTATOR DIAMETER Using vernier calipers, measure the commutator diameter. Standard diameter: 1.4 kW type: 30 mm (1.18 in.) 2.0 kW type: 35 mm (1.38 in.) Minimum diameter: 1.4 kW type: 29 mm (1.14 in.) 2.0 KW type: 34 mm (1.34 in.) If the diameter is less than minimum, replace the armature. 6. INSPECT UNDERCUT DEPTH Check that the undercut depth is clean and free of foreign materials. Smooth out the edge. Standard undercut depth: 1.4 kW type: 0.6 mm (0.024 in.) 2.0 kW type: 0.7 mm (0.028 in.) Minimum undercut depth: 0.2 mm (0.008 in.) If the undercut depth is less than minimum, correct it with a hacksaw blade. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark ST−8 STARTING − STARTER 7. INSPECT FIELD COIL FOR OPEN CIRCUIT Using an ohmmeter, check that there is continuity between the lead wire and field coil brush lead. If there is no continuity, replace the field frame. Ohmmeter Continuity P10588 8. INSPECT FIELD COIL FOR GROUND Using an ohmmeter, check that there is no continuity between the field coil end and field frame. If there is continuity, repair or replace the field frame. Ohmmeter No Continuity P10589 9. INSPECT BRUSH LENGTH Using vernier calipers, measure the brush length. Standard length: 1.4 kW type:15.5 mm (0.610 in.) 2.0 kW type:15.0 mm (0.591 in.) Minimum length: 1.4 kW type: 10.0 mm (0.394in.) 2.0 KW type: 9.0 mm (0.354 in.) If the length is less than minimum, replace the brush holder and field frame. Brush Holder Side Length Field Frame Side Length Z14910 10. INSPECT BRUSH SPRING LOAD Take the pull scale reading the instant the brush spring separates from the brush. Standard spring installed load: 1.4 kW type: 17.6 − 23.5 N (1.79 − 2.41 kgf, 4.0 − 5.3 lbf) 2.0 kW type: 21.5 − 27.5 N (2.19 − 2.80 kgf, 4.8 − 6.2 lbf) ST0019 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark ST−9 STARTING − STARTER Minimum spring installed load: 1.4 kW type: 11.8 N (1.20 kgf, 2.7 lbf) 2.0 kW type: 12.7 N (1.29 kgf, 2.9 lbf) If the installed load is less than minimum replace the brush springs. Ohmmeter No Continuity P21088 Free Lock 11. INSPECT BRUSH HOLDER INSULATION Using an ohmmeter, check that there is no continuity between the positive (+) and negative (−) brush holders. If there is continuity, repair or replace the brush holder. 12. 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. 13. INSPECT CLUTCH PINION GEAR Hold the starter clutch and rotate the pinion gear clockwise, and check that it turns freely. Try to rotate the pinion gear counterclockwise and check that it locks. If necessary, replace the clutch assembly. P10821 14. INSPECT REAR BEARING Turn each bearing by hand while applying inward force. If resistance is felt or the bearing sticks, replace the bearing. 15. INSPECT FRONT BEARING Turn each bearing by hand while applying inward force. If resistance is felt or the bearing sticks, replace the bearing. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark ST−10 STARTING − STARTER 16. DO PULL−IN COIL OPEN CIRCUIT TEST Using an ohmmeter, check that there is continuity between terminals 50 and C. If there is no continuity, check and replace the magnetic switch. Ohmmeter Terminal C Terminal 50 P08508 17. DO HOLD−IN COIL OPEN CIRCUIT TEST Using an ohmmeter, check that there is continuity between terminal 50 and the switch body. If there is no continuity, replace the magnetic switch. Switch Body Terminal 50 P08509 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark ST−11 STARTING SST − STARTER REPLACEMENT 1. (a) (b) ST0N9−01 REPLACE REAR BEARING Using SST, remove the bearing. SST 09286−46011 Using a press, press in a new rear bearing. P10593 2. (a) SST REPLACE FRONT BEARING Using SST, remove the bearing. SST 09286−46011 P10595 Upword SST Downword (b) Using a press, press in a new front bearing. NOTICE: Be careful of the bearing installation direction. SST 09820−00030 P10596 3. REMOVE MAGNETIC SWITCH END COVER Remove the 3 bolts, lead clamp, end cover, gasket and plunger. 4. INSPECT CONTACT PLATE FOR WEAR Using vernier calipers, measure the contact plate for depth of wear. Maximum wear: 0.9 mm (0.035 in.) If the depth of wear is greater than the maximum, replace the contact plate. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark ST−12 STARTING 5. (a) (b) (c) 6. (a) − STARTER REMOVE TERMINAL KIT PARTS Using SST, loosen the terminal nuts. SST 09810−38140 Terminal C: Remove the terminal nut, wave washer, terminal insulator (outside), O−ring, terminal bolt, contact plate and terminal insulator (inside). Terminal 30: Remove the terminal nut, wave washer, terminal insulator (outside), packing, O−ring, terminal bolt, contact plate, terminal insulator (inside) and insulation paper. REINSTALL TERMINAL KIT PARTS Terminal 30: Install these new parts: (1) Insulation paper (2) Terminal insulator (inside) (3) Contact plate (4) Terminal bolt (5) O−ring (6) Packing and terminal insulator (outside) Install the packing to the terminal insulator, and install them. HINT: Match the protrusion of the insulator with the indentation of the housing. (7) Wave washer (8) Terminal nut NOTICE: Be careful to install the terminal insulators (inside) and wave washers in the correct direction. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark ST−13 STARTING − STARTER (b) Terminal C: Install these new parts: (1) Terminal insulator (inside) (2) Contact plate (3) Terminal bolt (4) O−ring (5) Terminal insulator (outside) (6) Wave washer (7) Terminal nut NOTICE: Be careful to install the terminal insulators (inside) and wave washers in the correct direction. (c) Temporarily tighten the terminal nuts. 7. (a) TIGHTEN TERMINAL NUT Put a wooden block on the contact plate and press it down with a hand press. Dimensions of wooden block: 20 x 37 x 40 mm (0.79 x 1.46 x 1.57 in.) Press force: 981 N (100 kgf, 221 lbf) NOTICE: Check the diameter of the hand press ram. Then calculate the gauge pressure of the press when 981 N (100 kgf, 221 lbf) of force is applied. Gauge pressure: V06796 If the contact plate is not pressed down with the specified pressure, the contact plate may tilt due to coil deformation or the tightening of the nut. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark ST−14 STARTING − STARTER (b) Using SST, tighten the nuts to the specified torque. SST 09810−38140 Torque: 17 N·m (173 kgf·cm, 12 ft·lbf) NOTICE: If the nut is over tightened, it may cause cracks on the inside of the insulator. 8. CLEAN CONTACT SURFACES OF CONTACT PLATE AND PLUNGER Clean the contact surfaces of the remaining contact plate and plunger with a dry shop rag. 9. REINSTALL MAGNETIC SWITCH END COVER Install the plunger, new gasket, end cover and lead clamp with the 3 bolts. Torque: 1.4 kW type: 2.5 N·m (25 kgf·cm, 22 in.·lbf) 2.0 kW type: 3.6 N·m (37 kgf·cm, 32 in.·lbf) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark ST−15 STARTING − STARTER ST08G−03 REASSEMBLY Reassembly is in the reverse order of disassembly (See page ST−5). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark ST−16 STARTING − STARTER TEST ST08H−03 NOTICE: These tests must be performed within 3 to 5 seconds to avoid burning out the coil. 1. (a) (b) Terminal C Terminal 50 DO PULL−IN TEST Disconnect the field coil lead wire from terminal C. Connect the battery to the magnetic switch as shown. Check that the clutch pinion gear moves outward. BatteryP23047 2. DO HOLD−IN TEST With battery connected as above with the clutch pinion gear out, disconnect the negative (−) lead from terminal C. Check that the pinion gear remains out. Disconnect Battery P23049 3. (a) (b) INSPECT CLUTCH PINION GEAR RETURN Disconnect the negative (−) lead from the switch body. Check that the clutch pinion gear returns inward. 4. (a) (b) DO NO−LOAD PERFORMANCE TEST Connect the battery and ammeter to the starter as shown. Check that the starter rotates smoothly and steadily with the pinion gear moving out. Check that the ammeter shows the specified current. Specified current: 1.4 kW type At 11.5V: 90 A or less 2.0 kW type At 11.5V: 100 A or less DIsconnect BatteryP23048 Terminal 30 Terminal 50 Ammeter Battery P23050 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark ST−17 STARTING − STARTER ST0KT−01 INSTALLATION Installation is in the reverse order of removal (See page ST−4). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark TR−1 TRANSFER − TRANSFER SYSTEM TRANSFER SYSTEM TR0AX−01 PRECAUTION S S S S S S When working with FIPG material, you must observe the following. Using a razor blade and gasket scraper, remove all the old FIPG material from the gasket surfaces. Thoroughly clean all components to remove all the loose material. Clean both sealing surfaces with a non−residue solvent. Apply FIPG in an approx. 1 mm (0.04 in.) wide bead along the sealing surface. Parts must be assembled within 10 minutes of application. Otherwise, the FIPG material must be removed and reapplied. 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 811 Brought to you by BirfMark TR−3 TRANSFER − TRANSFER ASSEMBLY TRANSFER ASSEMBLY TR0B2−01 COMPONENTS L4 Position Switch Neutral Position Switch Dynamic Damper L z z x9 Rear Case Retainer Adjusting Shim Center Differential Assembly x8L x5 Vehicle Speed Sensor Driven Gear Oil Strainer Case Cover Bearing Race Bearing Race Rear Extension Housing Slotted Spring Pin x5L Shift Fork No.1 Shift Fork No.1 Shaft Snap Ring Bearing Race Idler Gear Assembly Bearing Race Input Shaft Assembly Motor Actuator Shift Outer Lever Output Gear L Screw Plug Spring Ball Snap Ring Shift Fork No.2 Shaft Shift Fork No.2 Lever Lock Pin Washer z Oil Seal Shift Inner Lever Oil Receiver Center Diff Lock Front Case Indicator Switch Breather Hose z Oil Seal Clutch Sleeve Front Extension Housing z Non−reusable part L Precoated part Q08382 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 813 Brought to you by BirfMark TR−4 TRANSFER − TRANSFER ASSEMBLY DISASSEMBLY TR0CM−01 1. REMOVE BREATHER HOSE 2. REMOVE DYNAMIC DAMPER Remove the 2 bolts and dynamic damper. HINT: At the time of reassembly, apply adhesive to the bolt threads. Adhesive: Part No.08833−00070, THREE BOND 1324 or equivalent Torque: 37 N·m (380 kgf·cm, 27 ft·lbf) 3. REMOVE MOTOR ACTUATOR Remove the 4 bolts and motor actuator. HINT: At the time of reassembly, please refer to the following items. S Set the motor actuator in differential lock condition. S Apply FIPG to the front case. FIPG: Part No. 08826−00090, THREE BOND 1281 or equivalent Torque: 18 N·m (185 kgf·cm, 13 ft·lbf) 4. REMOVE OUTPUT GEAR FROM FRONT CASE HINT: At the timie of reassembly apply gear oil to the output gear. NOTICE: At the time of reassembly, do not turn the output gear. 5. (a) REMOVE SCREW PLUG, SPRING AND BALL Using a torx socket wrench (T40), remove the screw plug. Q07105 HINT: At the time of reassembly, apply liquid sealer to the screw plug. Sealant: Part No.08833−00080, THREE BOND 1344, LOCTITE 242 or equivalent Torque:19 N·m (190 kgf·cm, 14 ft·lbf) (b) Using a magnetic finger, remove the spring and ball. FIPG Q07124 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark TR−5 TRANSFER Q04610 − TRANSFER ASSEMBLY 6. REMOVE TRANSFER INDICATOR SWITCH Remove the Center Diff Lock indicator switch, L4 position switch, Neutral position switch and 3 gaskets. Torque: 37 N·m (380 kgf·cm, 27 ft·lbf) 7. REMOVE FRONT EXTENSION HOUSING Remove the 6 bolts and front extension housing. HINT: If necessary, tap the front extension housing with a plastic hammer. HINT: At the time of reassembly, please refer to the following items. S Set the clutch sleeve in differential lock condition. S Apply FIPG to the front case. FIPG: Part No. 08826−00090, THREE BOND 1281 or equivalent Torque: 37 N·m (380 kgf·cm, 27 ft·lbf) 8. REMOVE CLUTCH SLEEVE, SHIFT FORK NO.2 SHAFT AND SHIFT FORK NO.2 HINT: At the time of reassebly, make sure to install the clutch sleeve in the correct direction. Front Q00541 9. (a) (b) SEPARATE SHIFT FORK NO.2 SHAFT AND SHIFT FORK NO.2 Using 2 screwdrivers and a hammer, tap out the 3 snap rings from the shift fork No.2 shaft. Separate the shift fork No.2 shaft and shift fork No.2. Q02950 FIPG Q07125 10. REMOVE REAR EXTENSION HOUSING Remove the 9 bolts and rear extension housing. HINT: If necessary, tap the rear extension housing with a plastic hammer. HINT: At the time of reassembly, apply FIPG to the rear case. FIPG: Part No. 08826−00090, THREE BOND 1281 or equivalent Torque: 37 N·m (380 kgf·cm, 27 ft·lbf) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark TR−6 TRANSFER − TRANSFER ASSEMBLY 11. REMOVE RETAINER FROM REAR CASE Remove the 5 bolts and retainer. Torque: 39 N·m (400 kgf·cm, 28 ft·lbf) 12. REMOVE ADJUSTING SHIM HINT: At the time of assembly, select adjusting shims for the idler gear rear taper roller bearing. (a) Using vernier calipers, measure dimension A. (b) Lightly hold down the bearing outer race in the thrust direction to eliminate any looseness before making the measurement. (c) B Using a steel straight edge and feeler gauge, measure the clearance of dimension B. Calculate the required thickness of the adjusting shim. Thickness: Dimension A + Dimension B + (0.022 − 0.049 mm, 0.0009 − 0.0019 in.) From the following table, select a shim so that its thickness is within the range of the calculation. (d) (e) Z18976 C Z18977 Mark Thickness mm (in.) Mark Thickness mm (in.) 2 0.30 (0.0118) 8 3.20 (0.1260) 3 0.45 (0.0177) 9 3.40 (0.1339) 4 2.40 (0.0945) 10 3.60 (0.1417) 5 2.60 (0.1024) 11 3.80 (0.1496) 6 2.80 (0.1102) 12 4.00 (0.1575) 7 3.00 (0.1181) 13 0.55 (0.0216) HINT: At the time of reassembly, select adjusting shims for the output shaft taper roller bearing. (f) Using a steel straight edge and feeler gauge, measure the clearance of dimension C. (g) Lightly hold down the bearing outer race in the thrust direction to eliminate any looseness before making the measurement. (h) Calculate the required thickness of the adjusting shim. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark TR−7 TRANSFER − TRANSFER ASSEMBLY Thickness: Dimension C + (0.014 − 0.039 mm, 0.0006 − 0.0015 in.) From the following table, select a shim so that its thickness is within the range of the calculation. (i) Mark Thickness mm (in.) Mark Thickness mm (in.) B 0.30 (0.0118) H 1.80 (0.0709) C 0.45 (0.0177) J 2.00 (0.0787) D 1.00 (0.0394) K 2.20 (0.0866) E 1.20 (0.0472) L 2.40 (0.0945) F 1.40 (0.0551) M 2.60 (0.1024) G 1.60 (0.0630) N 0.55 (0.0216) 13. REMOVE OIL STRAINER FROM REAR CASE Remove the 2 set bolts and oil strainer. Torque: 4.9 N·m (50 kgf·cm, 43 in.·lbf) 14. REMOVE CASE COVER (a) Remove the 5 bolts. FIPG Q07126 FIPG A Q08404 HINT: At the time of reassembly, apply liquid sealer to the bolt threads. Sealant: Part No.08833−00080, THREE BOND 1344, LOCTITE 242 or equivalent Torque: 37 N·m (380 kgf·cm, 27 ft·lbf) (b) Using a brass bar and hammer, tap the case cover and remove it. HINT: At the time of reassembly, apply FIPG to the rear case. FIPG: Part No. 08826−00090, THREE BOND 1281 or equivalent 15. SEPARATE FRONT CASE AND REAR CASE (a) Using a snap ring expander, remove the snap ring from the rear case. (b) Remove the 8 bolts. HINT: At the time of reassembly, apply liquid sealer to the ”A” bolt threads. Sealant: Part No.08833−00080, THREE BOND 1344, LOCTITE 242 or equivalent Torque:37 N·m (380 kgf·cm, 27 ft·lbf) (c) Using a brass bar and hammer, tap the rear case and separate it. HINT: At the time of reassembly, apply FIPG to the front case. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark TR−8 TRANSFER − TRANSFER ASSEMBLY FIPG: Part No. 08826−00090, THREE BOND 1281 or equivalent 16. REMOVE 2 BEARING RACES FROM REAR CASE 17. REMOVE INPUT SHAFT ASSEMBLY Using a plastic hammer, remove the input shaft assembly. TF0854 18. REMOVE IDLER GEAR ASSEMBLY, CENTER DIFFERENTIAL ASSEMBLY, SHIFT FORK NO.1 AND SHIFT FORK NO.1 SHAFT FROM FRONT CASE 19. SEPARATE SHIFT FORK NO.1 AND SHIFT FORK NO.1 SHAFT Using a pin punch and hammer, drive out the slotted spring pin. Separate the shift fork No.1 and shift fork No.1 shaft. TF0986 (a) (b) TF0857 Removal Socket Wrench Installation Socket Wrench Q07130 20. (a) REMOVE SHIFT OUTER LEVER AND INNER LEVER Remove the nut and washer from the shift outer lever. Torque: 12 N·m (120 kgf·cm, 9 ft·lbf) (b) Using a brass bar, hammer and socket wrench, tap out the lever lock pin. (c) Remove the shift outer lever, washer and inner lever from the front case. 21. REMOVE OIL RECEIVER FROM FRONT CASE Remove the bolt and oil receiver. Torque: 12 N·m (120 kgf·cm, 9 ft·lbf) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark TR−9 TRANSFER 22. (a) − TRANSFER ASSEMBLY REMOVE 2 BEARING RACES FROM FRONT CASE Using SST, remove the bearing race (for idler gear). SST 09950−40010, 09950−60010 (09951−00320) SST Q07131 HINT: At the time of reassembly, please refer to the following item. Using SST and a press, install the bearing race (for idler gear). SST 09316−60011 (09316−00011, 09316−00041) (b) Using a brass bar and hammer, remove the bearing race (for output shaft). TF0867 HINT: At the time of reassembly, please refer to the following item. Using SST and a press, install the bearing race (for the out put shaft). SST 09316−20011, 09316−60011 (09316−00011, 09316−00031) 23. INSPECT TRANSFER INDICATOR SWITCH Check that there is continuity between the terminals, as shown. Switch Position Specified Push Continuity Free No continuity If continuity is not as specified, replace the switch. Push Free I19645 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark TR−10 TRANSFER − TRANSFER ASSEMBLY REPLACEMENT TR0CN−01 1. (a) (b) REPLACE SHIFT LEVER OIL SEAL Using a screwdriver, pry out the oil seal. Using SST and a hammer, drive in a new oil seal. SST 0608−00081, 09950−70010 (09951−07150) 2. (a) REPLACE INPUT SHAFT OIL SEAL Using SST and a hammer, drive out the oil seal. SST 09316−60011 (09316−00011) (b) Using SST and a hammer, drive in a new oil seal. SST 09316−60011 (09316−00011, 09316−00031) SST TF0862 SST TF0863 SST SST TF0864 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark TR−11 TRANSFER − TRANSFER ASSEMBLY TR0B4−01 REASSEMBLY Reassembly is in the reverse order of disassembly (See page TR−4). HINT: Coat all of the sliding and rotating surfaces with gear oil before assembly. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark TR−12 TRANSFER − INPUT SHAFT INPUT SHAFT TR0B5−01 COMPONENTS 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 822 Brought to you by BirfMark TR−13 TRANSFER − INPUT SHAFT DISASSEMBLY Socket Wrench TR0B6−01 1. (a) (b) REMOVE REAR BALL BEARING Using a snap ring expander, remove the snap ring. Using a socket wrench and press, remove the rear ball bearing. 2. (a) (b) REMOVE INPUT GEAR Using a snap ring expander, remove the snap ring. Using a press, remove the input gear. TF0870 3. REMOVE FRONT BALL BEARING Using a press, remove the front ball bearing. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark TR−14 TRANSFER − INPUT SHAFT TR0B7−01 REASSEMBLY HINT: Coat all of the sliding and rotating surfaces with gear oil before assembly. 1. INSTALL FRONT BALL BEARING Using SST and a press, install a new front ball bearing. SST 09527−30010 Q00533 2. (a) INSTALL INPUT GEAR Using a press, install the input gear. (b) Select a snap ring that will allow minimum axial play. Mark Thickness mm (in.) Mark Thickness mm (in.) A 2.00 (0.0787) F 2.50 (0.0984) B 2.10 (0.0827) G 2.60 (0.1024) C 2.20 (0.0866) H 2.70 (0.1063) D 2.30 (0.0906) J 2.80 (0.1102) E 2.40 (0.0945) − − (c) Using a snap ring expander, install a new snap ring. 3. (a) INSTALL REAR BALL BEARING Using SST and a press, install a new rear ball bearing. SST 09316−60011 (09316−00031) (b) Select a snap ring that will allow minimum axial play. (c) Mark Thickness mm (in.) A 2.00 (0.0787) B 2.10 (0.0827) C 2.20 (0.0866) D 2.30 (0.0906) E 2.40 (0.0945) Using a snap ring expander, install a new snap ring. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark TR−15 TRANSFER − IDLER GEAR IDLER GEAR TR0B8−01 COMPONENTS Front Taper Roller Bearing Idler Gear Rear Taper Roller Bearing Idler Low Gear Needle Roller Bearing High and Low Clutch Sleeve Z15264 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 825 Brought to you by BirfMark TR−16 TRANSFER − IDLER GEAR DISASSEMBLY 1. (a) TF0887 (b) TR0B9−01 INSPECT IDLER LOW GEAR RADIAL AND THRUST CLEARANCE Using a feeler gauge, measure the idler low gear thrust clearance. Standard clearance: 0.125−0.275 mm (0.0049−0.0108 in.) Maximum clearance: 0.275 mm (0.0108 in.) Using a dial indicator, measure the idler low gear radial clearance. Standard clearance: 0.015−0.068 mm (0.0006−0.0027 in.) Maximum clearance: 0.068 mm (0.0027 in.) TF0888 2. REMOVE FRONT TAPER ROLLER BEARING Using SST, remove the front taper roller bearing. SST 09950−40010 SST Q07132 3. REMOVE REAR TAPER ROLLER BEARING Using SST, a press and socket wrench, remove the rear taper roller bearing. SST 09950−00020 4. REMOVE IDLER LOW GEAR AND NEEDLE ROLLER BEARING FROM IDLER GEAR 5. REMOVE HIGH AND LOW CLUTCH SLEEVE FROM IDLER GEAR Socket Wrench Q07100 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark TR−17 TRANSFER − IDLER GEAR REASSEMBLY TR0BA−01 HINT: Coat all of the sliding and rotating surfaces with gear oil before assembly. 1. INSTALL FRONT TAPER ROLLER BEARING Using SST and a press, install the front taper roller bearing. SST 09316−60011 (09316−00011, 09316−00031) SST TF0893 2. INSTALL HIGH AND LOW CLUTCH SLEEVE HINT: Make sure to install the high and low clutch sleeve in the correct direction. 3. INSTALL NEEDLE ROLLER BEARING AND IDLER LOW GEAR TO IDLER GEAR (a) Apply gear oil to the needle roller bearing. (b) Install the needle roller bearing and idler low gear. Q00538 4. INSTALL REAR TAPER ROLLER BEARING Using SST and a press, install the rear taper roller bearing. SST 09316−60011 (09316−00011, 09316−00071) 5. INSPECT IDLER LOW GEAR RADIAL AND THRUST CLEARANCE (See page TR−16) SST TF0896 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark TR−18 TRANSFER − CENTER DIFFERENTIAL CENTER DIFFERENTIAL TR0BB−01 COMPONENTS High Speed Output Gear Bushing High Speed Output Gear Front Drive Gear Piece Rear Taper Roller Bearing Clutch Hub z Snap Ring High and Low Clutch Sleeve Needle Roller Bearing Needle Roller Bearing Thrust Washer Rear Side Gear Front Taper Roller Bearing Thrust Washer z Snap Ring Pinion Gear Straight Pin x 12 Straight Pin Low Gear Differential Rear Case Pinion Shaft Front Side Gear Thrust Washer Differential Front Case Pinion Gear Thrust Washer z Non−reusable part Q07134 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 828 Brought to you by BirfMark TR−19 TRANSFER − CENTER DIFFERENTIAL DISASSEMBLY 1. (a) TF0900 (b) TR0BC−01 INSPECT HIGH SPEED OUTPUT GEAR RADIAL AND THRUST CLEARANCE Using a feeler gauge, measure the high speed output gear thrust clearance. Standard clearance: 0.10−0.25 mm (0.0039−0.0098 in.) Maximum clearance: 0.25 mm (0.0098 in.) Using a dial indicator, measure the high speed output gear radial clearance. Standard clearance: 0.035−0.091 mm (0.0014−0.0036 in.) Maximum clearance: 0.091 mm (0.0036 in.) TF0944 2. (a) (b) REMOVE FRONT DRIVE GEAR PIECE Using a snap ring expander, remove the snap ring. Using SST and a press, remove the front drive gear piece. SST 09950−00020, 09950−60010 (09951−00320) NOTICE: Be careful not to drop the center differential assembly. SST Q07101 SST 3. REMOVE FRONT TAPER ROLLER BEARING Using SST and a press, remove the front taper roller bearing. SST 09950−00020 4. REMOVE HIGH SPEED OUTPUT GEAR 5. REMOVE NEEDLE ROLLER BEARING 6. REMOVE HIGH AND LOW CLUTCH SLEEVE ASSEMBLY Q07102 7. (a) SST (b) REMOVE HIGH SPEED OUTPUT GEAR BUSHING AND CLUTCH HUB Using SST and a press, remove the high speed output gear bushing and clutch hub. SST 09550−00020, 09950−00030, 09950−60010 (09951−00320) Using a magnetic finger, remove the straight pin from the differential front case. Q07103 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark TR−20 TRANSFER SST Q07113 SST Bearing CENTER DIFFERENTIAL 8. REMOVE REAR TAPER ROLLER BEARING Using SST and a press, remove the rear taper roller bearing. SST 09950−00020, 09950−60010 (09951−00320) 9. REMOVE DIFFERENTIAL REAR CASE Remove the 12 bolts and differential rear case. 10. REMOVE REAR SIDE GEAR AND THRUST WASHER 11. REMOVE PINION SHAFT, PINION GEAR AND THRUST WASHER (a) Remove the straight pin from the pinion shaft. (b) Remove the pinion shaft, 2 pinion gears and thrust washers. (c) Remove the front side gear and thrust washer. 12. REMOVE LOW GEAR Using a plastic hammer, tap and remove the low gear. NOTICE: Be careful not to damage the low gear. 13. (a) (b) SST − REMOVE NEEDLE ROLLER BEARING Using a screwdriver, remove the snap ring. Using SST and a hammer, remove the needle roller bearing from the differential rear case. SST 09223−00010, 09950−60010 (09951−00400), 09950−70010 (09951−07150) Q07114 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark TR−21 TRANSFER Stamp SST Q07115 − CENTER DIFFERENTIAL TR0BD−01 REASSEMBLY HINT: Coat all of the sliding and rotating surfaces with gear oil before assembly. 1. INSTALL NEEDLE ROLLER BEARING (a) Using SST and a press, install the needle roller bearing to the differential rear case. SST 09612−24014 (09612−10050) HINT: Install the bearing to the differential rear case, taking care that its stamped side comes in contact with SST. (b) Install the snap ring. 2. INSTALL LOW GEAR (a) Clean the contact surface of the differential case. (b) Heat the low gear in boiling water. (c) Carefully remove the low gear from the water. (d) After the moisture on the low gear has completely evaporated, quickly install the low gear to the differential case. 3. (a) INSTALL PINION SHAFT, PINION GEAR AND THRUST WASHER Install the front side gear and thrust washer to the differential front case. TF1012 (b) Install the pinion shaft, 2 pinion gears and thrust washers to the differential front case. TF0913 (c) Using a dial indicator, measure the front case backlash. HINT: Push the pinion shaft. Minimum backlash: 0.05 mm (0.0020 in.) If the backlash is not within the specification, replace the thrust washer with one of the correct size and reinstall the thrust washer. TF0917 Thickness mm (in.) Thickness mm (in.) 1.70 (0.0669) 2.45 (0.0965) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark TR−22 TRANSFER − CENTER DIFFERENTIAL 1.85 (0.0728) 2.60 (0.1024) 2.00 (0.0787) 2.75 (0.1083) 2.15 (0.0846) 2.90 (0.1142) 2.30 (0.0906) 3.05 (0.1201) (d) In the same way, measure the rear case backlash. 4. INSTALL STRAIGHT PIN TO PINION SHAFT 5. INSTALL REAR SIDE GEAR AND THRUST WASHER 6. INSTALL DIFFERENTIAL REAR CASE Install the differential rear case and 12 set bolts. 7. (a) (b) (c) (d) TORQUE REAR CASE SET BOLT Torque the rear case 12 set bolts. Torque: 88 N·m (900 kgf·cm, 65 ft·lbf) Turn the pinion gear. Loosen the rear case 12 set bolts. Torque the rear case 12 set bolts. Torque: 98 N·m (1,000 kgf·cm, 72 ft·lbf) TF0920 8. INSTALL REAR TAPER ROLLER BEARING Using SST and a press, install the rear taper roller bearing. SST 09316−12010 SST Q00534 9. INSTALL CLUTCH HUB Using SST and a press, install the clutch hub. SST 09316−12010, 09316−60011 (09316−00011) SST Q00547 10. (a) (b) INSTALL HIGH SPEED OUTPUT GEAR BUSHING Apply MP grease to the straight pin. Install the straight pin, as shown. Q00549 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark TR−23 TRANSFER − CENTER DIFFERENTIAL (c) Using SST and a press, install the high speed output gear bushing. SST 09316−12010, 09316−60011 (09316−00011) NOTICE: Before pressing, align the holes on the bushing and shaft so that the pin on the shaft aligned with the cutting portion of the bushing. SST Q00546 Q00555 11. INSTALL HIGH AND LOW CLUTCH SLEEVE HINT: Make sure to install the high and low clutch sleeve in the correct direction. 12. INSTALL HIGH SPEED OUTPUT GEAR AND NEEDLE ROLLER BEARING (a) Apply gear oil to the needle roller bearing. (b) Install the high speed output gear and needle roller bearing. 13. INSTALL FRONT TAPER ROLLER BEARING Using SST and a press, install the front taper roller bearing. SST 09316−12010, 09316−60011 (09316−00011) SST SST Q00539 14. INSTALL FRONT DRIVE GEAR PIECE Using SST and a press, install the front drive gear piece. SST 09316−12010, 09316−60011 (09316−00011) SST SST Q00540 15. (a) TF0931 INSTALL SNAP RING Select a snap ring that will allow minimum axial play. Mark Thickness mm (in.) Mark Thickness mm (in.) A 2.00 (0.0787) G 2.60 (0.1024) B 2.10 (0.0827) H 2.70 (0.1063) C 2.20 (0.0866) J 2.80 (0.1102) D 2.30 (0.0906) K 1.80 (0.0709) E 2.40 (0.0945) L 1.90 (0.0748) F 2.50 (0.0984) − − 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark TR−24 TRANSFER (b) 16. − CENTER DIFFERENTIAL Using a snap ring expander, install a new snap ring. INSPECT HIGH SPEED OUTPUT GEAR RADIAL AND THRUST CLEARANCE (See page TR−19) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark TR−25 TRANSFER − FRONT EXTENSION HOUSING FRONT EXTENSION HOUSING TR0BE−01 COMPONENTS z Dust Deflector z Snap Ring Front Output Shaft Drive Clutch Hub z Snap Ring z Snap Ring Ball Bearing z Oil Seal Housing Z18836 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 835 Brought to you by BirfMark TR−26 TRANSFER − FRONT EXTENSION HOUSING DISASSEMBLY 1. (a) (b) TR0BF−01 REMOVE DRIVE CLUTCH HUB Using a snap ring expander, remove the snap ring. Using SST, remove the drive clutch hub. SST 09950−40010 SST Q07133 2. REMOVE FRONT OUTPUT SHAFT Using a plastic hammer, drive out the front output shaft. 3. REMOVE DUST DEFLECTOR (a) Using SST and a press, remove the dust deflector. SST 09950−00020 (b) Using a screwdriver and hammer, tap the dust deflector and remove it from the extension housing. 4. REMOVE OIL SEAL Using a screwdriver, pry out the oil seal from the front extension housing. TF0938 5. (a) (b) SST REMOVE BALL BEARING Using a screwdriver, remove the snap ring. Using SST and a press, remove the ball bearing. SST 09316−60011 (09316−00011, 09316−00071) TF0940 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark TR−27 TRANSFER − FRONT EXTENSION HOUSING TR0BG−01 REASSEMBLY HINT: Coat all of the sliding and rotating surfaces with gear oil before assembly. 1. INSTALL DUST DEFLECTOR (a) Using SST and a press, install a new dust deflector to the front extension housing. SST 09223−15020, 09950−70010 (09951−07150) (b) Using SST and a press, install a new dust deflector to the front output shaft. SST 09316−20011, 09316−60011 (09316−00011) 2. (a) INSTALL BALL BEARING Using SST and a press, install the ball bearing to the front extension housing. SST 09316−60011 (09316−00011, 09316−00031) (b) Select a snap ring that will allow minimum axial play. SST TF0967 SST TF0943 (c) Mark Thickness mm (in.) A 1.7 (0.0669) B 1.8 (0.0709) Using a screwdriver, install a new snap ring. TF0939 3. INSTALL OIL SEAL Using SST and a hammer, drive in a new oil seal to the front extension housing. SST 09316−60011 (09316−00011, 09316−00061) SST TF0945 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark TR−28 TRANSFER 4. (a) SST − FRONT EXTENSION HOUSING INSTALL FRONT OUTPUT SHAFT AND DRIVE CLUTCH HUB Using SST and a press, install the front output shaft and drive clutch hub. SST 09316−20011, 09316−60011 (09316−00011, 09316−00041, 09316−00071) SST Q00542 (b) Select a snap ring that will allow minimum axial play. Mark TF0933 (c) Thickness mm (in.) A 1.8 (0.0709) B 1.9 (0.0748) C 2.0 (0.0787) D 2.1 (0.0827) E 2.2 (0.0866) Using a snap ring expander, install a new snap ring. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark TR−29 TRANSFER − REAR EXTENSION HOUSING REAR EXTENSION HOUSING TR0BH−01 COMPONENTS Center Differential Control Couping Assembly Separator Rear Output Shaft z Dust Deflector Seal Ring z Oil Seal Snap ring Ball Bearing Vehicle Speed sensor Drive Gear Ball z Snap Ring Driven Rotor Snap Ring Oil Pump Cover Oil Pump Plate L Screw Plug Valve Seat Spring Rear Extension housing Oil Pump Drive Shaft Drive Rotor z Non−reusable Part L Precoated part Q08383 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 839 Brought to you by BirfMark TR−30 TRANSFER − REAR EXTENSION HOUSING DISASSEMBLY 1. 2. (a) (b) (c) Q00530 3. 4. 5. (a) (b) TR0BI−01 REMOVE OIL PUMP DRIVE SHAFT REMOVE OIL PUMP COVER Using a torx socket wrench (T30), remove the 3 screws. Install the 2 suitable bolts to the pump cover. Remove the pump cover from the rear extension housing. REMOVE DRIVE ROTOR FROM DRIVEN ROTOR REMOVE DRIVEN ROTOR FROM REAR EXTENSION HOUSING REMOVE SCREW PLUG, SPRING, BALL AND VALVE SEAT Using a hexagon wrench, remove the screw plug. Using a magnetic finger, remove the spring, ball and valve seat from the rear extension housing. Q08384 6. (a) (b) REMOVE CENTER DIFFERENTIAL CONTROL COUPLING ASSEMBLY Using a snap ring expander, remove the snap ring. Remove the coupling assembly from the rear extension housing. Q02549 7. REMOVE SEPARATOR AND OIL PUMP PLATE Remove the 3 bolts, separator and oil pump plate. 8. REMOVE VEHICLE SPEED SENSOR DRIVE GEAR (a) Using a snap ring expander, remove the snap ring. (b) Remove the vehicle speed sensor drive gear. Q07138 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark TR−31 TRANSFER 9. (a) (b) (c) − REAR EXTENSION HOUSING REMOVE REAR OUTPUT SHAFT Using a snap ring expander, remove the snap ring. Using SST and a hammer, remove the rear output shaft. SST 09325−12010 Remove the 2 seal rings from the rear output shaft. SST TF0959 10. (a) REMOVE DUST DEFLECTOR Using a screwdriver and hammer, remove the rear extension housing dust deflector. (b) Using a screwdriver and hammer, remove the rear output shaft dust deflector. 11. REMOVE OIL SEAL Using a screwdriver, pry out the oil seal from the rear extension housing. Q08385 12. (a) (b) SST REMOVE BALL BEARING Using a screwdriver, remove the snap ring. Using SST and a press, remove the ball bearing to the rear extension housing. SST 09316−60011 (09316−00011, 09316−00021) Q08481 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark TR−32 TRANSFER − REAR EXTENSION HOUSING INSPECTION TR0BJ−01 1. (a) (b) Q02615 INSPECT DRIVEN ROTOR BODY CLEARANCE Install the drive rotor to the driven rotor. Using a feeler gauge, measure the body clearance between the drive rotor and extension housing. Standard body clearance: 0.08−0.17 mm (0.0031−0.0067 in.) Maximum body clearance: 0.17 mm (0.0067 in.) If the body clearance exceeds the maximum, replace the drive rotor or driven rotor. 2. INSPECT DRIVEN ROTOR TIP CLEARANCE Using a feeler gauge, measure the tip clearance between the driver rotor and driven rotor. Standard tip clearance: 0.05−0.15 mm (0.0020−0.0059 in.) Maximum tip clearance: 0.15 mm (0.0059 in.) If the tip clearance exceeds the maximum, replace the drive rotor or driven rotor. Q02616 3. INSPECT OIL PUMP SIDE CLEARANCE Using a steel straight edge and feeler gauge, measure the side clearance of oil pump. Standard side clearance: 0.03−0.10 mm (0.0012−0.0039 in.) Maximum side clearance: 0.10 mm (0.0039 in.) If the side clearance exceeds the maximum, replace the drive rotor or driven rotor. Q02617 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark TR−33 TRANSFER − REAR EXTENSION HOUSING TR0CO−01 REASSEMBLY HINT: Coat all of the sliding and rotating surfaces with gear oil before assembly. 1. INSTALL BALL BEARING (a) Using SST and a press, install the ball bearing. SST 09316−60011 (09316−00011, 09316−00031) SST TF0964 (b) Select a snap ring that will allow minimum axial play. Mark Thickness mm (in.) A 1.7 (0.0669) B 1.8 (0.0709) (c) Using a screwdriver, install a new snap ring. 2. (a) INSTALL DUST DEFLECTOR Using SST and a hammer, install a new rear extension housing dust deflector. SST 09316−60011 (09316−00011, 09316−00041) (b) Using SST and a press, install a new rear output shaft dust deflector. SST 09316−20011, 09316−60011 (09316−00011) TF0962 SST Q08482 SST TF0967 3. INSTALL OIL SEAL Using SST and a hammer, drive in a new oil seal. SST 09316−60011 (09316−00011, 09316−00031) SST Q08482 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark TR−34 TRANSFER 4. (a) SST − REAR EXTENSION HOUSING (b) INSTALL REAR OUTPUT SHAFT Using SST and a press, install the rear output shaft. SST 09316−20011, 09316−60011 (09316−00011, 09316−00031) Install the 2 seal rings to the rear output shaft. (c) Select a snap ring that will allow minimum axial play. TF0969 Mark Thickness mm (in.) 1 1.95 (0.0768) 2 2.05 (0.0807) 3 2.15 (0.0847) 4 2.25 (0.0886) (d) Using a snap ring expander, install a new snap ring. 5. (a) (b) 6. (a) (b) (c) INSTALL VEHICLE SPEED SENSOR DRIVE GEAR Install the vehicle speed sensor drive gear. Using a snap ring expander, install the snap ring. INSTALL OIL PUMP PLATE AND SEPARATOR Install the oil pump plate. Install the separator. Install and torque the 3 bolts. Torque: 4.9 N·m (50 kgf·cm, 43 in.·lbf) 7. INSTALL CENTER DIFFERENTIAL CONTROL COUPLING ASSEMBLY Install the coupling assembly to the output shaft. Using a snap ring expander, install the snap ring. TF0958 Q07138 (a) (b) Q02549 8. (a) (b) (c) (d) Q08384 INSTALL VALVE SEAT, BALL, SPRING AND SCREW PLUG Apply gear oil to the ball. Install the valve seat, ball and spring. Apply liquid sealer to the screw plug. Sealant: Part No. 08833−00080, THREE BOND 1344, LOCTITE 242 or equivalent Using a hexagon wrench, install and torque the screw plug. Torque: 29 N·m (300 kgf·cm, 22 ft·lbf) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark TR−35 TRANSFER − REAR EXTENSION HOUSING 9. INSTALL DRIVEN ROTOR (a) Apply gear oil to the driven rotor. (b) Install the driven rotor. 10. INSTALL DRIVE ROTOR (a) Apply gear oil to the drive rotor. (b) Install the drive rotor. HINT: Align the alignment marks. TF0977 11. (a) (b) Q00529 INSTALL OIL PUMP COVER Install the oil pump cover. Using a torx socket wrench (T30), install and torque the 3 screws. Torque: 4.9 N·m (50 kgf·cm, 43 in.·lbf) NOTICE: Align the oil hole of the rear extension housing and oil groove end of the oil pump cover. 12. INSTALL OIL PUMP DRIVE SHAFT 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark TR−36 TRANSFER − MOTOR SHIFT CONTROL SYSTEM MOTOR SHIFT CONTROL SYSTEM TR0BL−01 LOCATION 1996 LAND CRUISER (RM451U) Author: Brought to you by BirfMark Version 1.11 - 03/16/2010 Date: 846 Brought to you by BirfMark TR−37 TRANSFER − MOTOR SHIFT CONTROL SYSTEM INSPECTION L H Light up Goes off N 1. (a) (b) DIFF LOCK DIFF LOCK TR0BM−03 INSPECT SHIFT LEVER POSITION Start the engine, and turn the center diff lock switch to OFF. Check that the center diff indicator light comes on when the transfer shift lever shifted to the ”L” position. Check that the light goes off when the lever is shifted to the ”N” or ”H” position. Q02622 2. (a) Relay Side INSPECT CENTER DIFF LOCK CONTROL RELAY Check that there is continuity between the terminals, as shown in the chart. V01699 Z15367 HINT: There is a diode between the terminals 6 and 7. If the circuit shown no continuity, change the positive (+) and negative (−) probes and recheck the circuit. (b) Apply battery positive voltage between the terminals and check that there is continuity between the terminals, as shown in the chart. V06651 If continuity is not as specified, replace the relay. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010 Brought to you by BirfMark TR−38 TRANSFER − MOTOR SHIFT CONTROL SYSTEM 3. (a) INSPECT MOTOR ACTUATOR Measure the resistance between the terminals 2 and 3. Standard resistance: 0.3 − 100 Ω (b) Measure the resistance between the terminals 2 or 3 and body ground. Standard resistance: More than 0.5 MΩ If the resistance value is not as specified, replace the motor actuator. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.11 - 03/16/2010