TOYOTA LAND CRUISER 1996 J80 Workshop Manual

SR2922
Alignment Marks
SR−48
−
STEERING STEERING LINKAGE
1996 LAND CRUISER (RM451U)
6. INSTALL PITMAN ARM
(a) 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 )
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SS00F−01
V06821
MarkMark
Class
Class
Hexagon head
bolt Bolt
head No.4−
5−
6−
7−
8−
9−
10−
11 − 4T
5T 6T
7T 8T
9T
10T 11 T
No mark
No mark
Hexagon
flange bolt
w/ washer
hexagon bolt 4T
4T
5T
6T
7T
8T
Hexagon
head
bolt
Hexagon
flange bolt w/ washer
hexagon bolt
Hexagon head
bolt
Hexagon head
bolt 2
Protruding
lines
2
Protruding
lines
3
Protruding
lines
4
Protruding
lines Hexagon
flange bolt
w/ washer
hexagon bolt
Hexagon
flange boltw/ washer
hexagon bolt
Hexagon
flange bolt
w/ washer
hexagon bolt
Stud bolt
Welded bolt 4
Protruding
lines
5
Protruding
lines
6
Protruding
lines
No mark
Grooved
9T
10T 11 T
4T
6T
4T
−
SERVICE SPECIFICATIONS STANDARD BOLT
SS−1
124
Author: Date:
1996 LAND CRUISER (RM451U)
STANDARD BOLT
HOW TO DETERMINE BOLT STRENGTH
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SS00G−01
V00079
ClassDiameter
mm Pitch
mm Specified torque
Hexagon head bolt
Hexagon flange bolt
N·m kgf·cm ft·lbf N·m kgf·cm
ft·lbf
in.·lbf
in.·lbf
in.·lbf in.·lbf
in.·lbf
in.·lbf
SS−2
−
SERVICE SPECIFICATIONS STANDARD BOLT
1996 LAND CRUISER (RM451U)
SPECIFIED TORQUE FOR STANDARD BOLTS
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SS1EN−01
−
SERVICE SPECIFICATIONS MAINTENANCE
SS−3
126
Author: Date:
1996 LAND CRUISER (RM451U)
MAINTENANCE
TORQUE SPECIFICATION
Part tightenedN·mkgf·cmft·lbf
Front seat mounting bolt3940029
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SS1EO−04
SS−4
−
SERVICE SPECIFICATIONS ENGINE MECHANICAL
127
Author: Date:
1996 LAND CRUISER (RM451U)
ENGINE MECHANICAL
SERVICE DATA
Compression
pressureat 250 rpm STD
Minimum
Difference of pressure between each cylinder1,176 kPa (12.0 kgf/cm2, 171 psi) or more
883 kPa (9.0 kgf/cm2, 128 psi)
98 kPa (1.0 kgf/cm2, 14 psi) or less
Valve clearanceat cold Intake Exhaust0.15 − 0.25 mm (0.006 − 0.010 in.)
0.25 − 0.35 mm (0.010 − 0.014 in.)
Ignition timingw/ Terminals TE1 and E1 connected3° BTDC @ idle
Idle speed−650 ± 50 rpm
Cylinder headWarpage
Cylinder block side Maximum
Manifold side Maximum
Valve seat
Refacing angle Intake
Exhaust
Contacting angle
Contacting width Intake
Exhaust
Cylinder head bolt outside diameter STD
Minimum
0.15 mm (0.0059 in.)
0.10 mm (0.0039 in.)
30°, 45° , 75°
45 °, 75°
45 °
1.2 − 1.6 mm (0.047 − 0.063 in.)
1.0 − 1.4 mm (0.039 − 0.055 in.)
10.85 − 11.00 mm (0.4272 − 0.4331 in.)
10.6 mm (0.417 in.)
Valve guide
bushingInside diameter
Outside diameter (for repair part) STD O/S 0.05
Protrusion height7.010 − 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.)
ValveValve overall length STD Intake
Exhaust
Minimum Intake Exhaust
Valve face angle
Stem diameter Intake
Exhaust
Stem oil clearance STD Intake
Exhaust
Maximum Intake
Exhaust
Margin thickness STD
Minimum98.4 mm (3.874 in.)
97.9 mm (3.854 in.)
97.9 mm (3.854 in.)
97.4 mm (3.835 in.)
44.5 °
6.970 − 6.985 mm (0.2744 − 0.2750 in.)
6.965 − 6.980 mm (0.2742 − 0.2748 in.)
0.025 − 0.060 mm (0.0010 − 0.0024 in.)
0.030 − 0.065 mm (0.0012 − 0.0026 in.)
0.08 mm (0.0031 in.)
0.10 mm (0.0039 in.)
1.2 mm (0.047 in.)
1.0 mm (0.039 in.)
Valve springDeviation Maximum
Free length
Installed tension at 36.5 mm (1.437 in.)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 lifterLifter diameter
Lifter bore diameter
Oil clearance STD
Maximum33.966 − 33.976 mm (1.3372 − 1.3376 in.)
34.000 − 34.021 mm (1.3386 − 1.3394 in.)
0.024 − 0.055 mm (0.0009 − 0.0022 in.)
0.07 mm (0.0028 in.)
ManifoldWarpage Maximum0.30 mm (0.0118 in.)
Air intake chamberWarpageMaximum0.30 mm (0.0118 in.)
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−
SERVICE SPECIFICATIONS ENGINE MECHANICAL
SS−5
128
Author: Date:
1996 LAND CRUISER (RM451U)
Camshaft
Thrust clearance
STD
Maximum
Journal oil clearance STD
Maximum
Journal diameter
Circle runout Maximum
Cam lobe height STD
Minimum
Camshaft gear backlash STD
Maximum
Camshaft gear spring end free distance0.030 − 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.)
0.06 mm (0.0024 in.)
50.61 − 50.71 mm (1.9925 − 1.9965 in.)
50.51 mm (1.9886 in.)
0.020 − 0.200 mm (0.0008 − 0.0079 in.)
0.30 mm (0.0188 in.)
18.2 − 18.8 mm (0.712 − 0.740 in.)
Spark plug tubeProtrusion45.5 mm (1.791 in.)
Oil pump drive
shaft gearThrust clearance STD
Maximum0.040 − 0.160 mm (0.0016 − 0.0063 in.)
0.30 mm (0.0188 in.)
Chain and timing
gearChain length at 16 links Maximum
Camshaft timing gear wear (w/ Chain) Minimum
Crankshaft timing gear wear (w/ Chain) Minimum146.6 mm (5.772 in.)
126.0 mm (4.961 in.)
65.4 mm (2.575 in.)
Chain tensioner
slipper and vibra-
tion damperWearMaximum1.0 mm (0.039 in.)
Cylinder blockCylinder head surface warpageMaximum
Cylinder bore diameter STD Mark 1
2
3
Maximum STD
O/S 0.50
O/S 1.00
Main bearing bolt outside diameter STD
Minimum0.05 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.)
Piston and piston
ringPiston diameter STD Mark 1
2
3
O/S 0.50
O/S 1.00
Piston oil clearance STD
Piston ring groove clearance No. 1
No. 2
Piston ring end gap STD No. 1
No. 2
Oil
Maximum No. 1 No. 2Oil99.950 − 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.)
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SS−6
−
SERVICE SPECIFICATIONS ENGINE MECHANICAL
129
Author: Date:
1996 LAND CRUISER (RM451U)
Connecting rod
Thrust clearance
STD
Maximum
Connecting rod bearing center wall thickness (Reference) Mark 23
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
Minimum0.160 − 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.)
CrankshaftThrust 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 Maximum0.020 − 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.)
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SS1EP−01
−
SERVICE SPECIFICATIONS ENGINE MECHANICAL
SS−7
1996 LAND CRUISER (RM451U)
TORQUE SPECIFICATION
Part tightenedN·mkgf·cmft·lbf
Distributor x Cylinder head1818013
No. 1 engine hanger x Cylinder head4142030
No. 2 engine hanger x Cylinder head4142030
Air intake chamber x Intake manifold2121015
Intake manifold x Cylinder head2121015
Heater inlet pipe x Intake manifold2121015
EGR pipe x Cylinder head2121015
EGR pipe x EGR valve Union nut7880058
Water outlet x Cylinder head2121015
Generator bracket x Cylinder head4344032
Cylinder head x Cylinder block 1st
2nd 3rd39
Turn 90°
Turn 90°400
Turn 90°
Turn 90°29
Turn 90°
Turn 90°
Cylinder head x Timing chain cover2121015
Camshaft bearing cap x Cylinder head1616012
Camshaft timing gear x Camshaft7475054
Chain tensioner x Cylinder head2121015
Water bypass outlet x Cylinder head2121015
Heater pipe x Timing chain cover2121015
Heater pipe x Cylinder head2020014
Exhaust manifold x Cylinder head3940029
Heat insulator x Exhaust manifold1919514
Front exhaust pipe x Exhaust manifold6363046
No. 1 support bracket x Transmission2424017
No. 1 support bracket clamp bolt19.519514
Front exhaust pipe x Rear TWC4647034
No. 2 water bypass pipe x Cylinder head2020014
No. 2 water bypass pipe x No. 1 engine hanger2020014
Fuel inlet hose x Fuel filter2930022
Intake manifold stay x Air intake chamber3636026
Intake manifold stay x Cylinder block3636026
Oil dipstick guide x Intake manifold2020014
Oil dipstick guide x No. 1 oil pan2020014
PS reservoir tank x Air intake chamber2020014
Oil jet x Cylinder block2020014
Vibration damper x Cylinder block2020014
Chain tensioner slipper x Cylinder block6970051
Timing chain cover x Cylinder block2121015
Drive belt idler pulley x Timing chain cover4344032
Crankshaft pulley x Crankshaft4124,200304
Transmission housing x No. 1 oil pan7273053
Oil level sensor x No. 1 oil pan5.45548 in.·lbf
Water pump x Cylinder block2121015
Radiator pipe x No. 1 oil pan2121015
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SS−8
−
SERVICE SPECIFICATIONS ENGINE MECHANICAL
1996 LAND CRUISER (RM451U)
A/C compressor bracket x No. 1 oil pan
3737527
A/C compressor bracket x Cylinder block3737527
A/C compressor x A/C compressor bracket2525018
Oil check valve x Cylinder block2525018
Main bearing cap x Cylinder block
1st
2nd74
Turn 90°750
Turn 90°54
Turn 90°
Connecting rod cap x Connecting rod 1st
2nd48
Turn 90°490
Turn 90°35
Turn 90°
Rear oil seal retainer x Cylinder block2121015
Oil cooler cover x Cylinder block2121015
LH engine mounting bracket x Cylinder block6970051
LH insulator x LH engine mounting bracket7273043
RH engine mounting bracket x Cylinder brock6970051
RH insulator x RH engine mounting bracket7273043
PS pump x Cylinder block3637027
Knock sensor x Cylinder block4445033
Oil filter union x Cylinder block4445033
Drive plate x Crankshaft1001,00074
Transmission x Cylinder block7273053
Transmission x No. 1 oil pan7273053
Torque converter clutch x Drive plate5555041
A/T oil cooler pipe x Union (Transmission)3435025
Starter x Transmission3940029
Frame crossmember x Frame6162045
Frame crossmember x Engine rear mounting insulator7475054
Engine front mounting insulator x Frame7475054
Transfer shift lever x Transmission1818513
Transmission shift lever assembly x Body5.45548 in.·lbf
Transmission control rod x Control shaft lever131309
Front propeller shaft x Front dif ferential7475054
Front propeller shaft x Transfer7475054
Rear propeller shaft x Rear differential8890065
Rear propeller shaft x Transfer8890065
Stabillizer bar bracket mounting bolt1818513
Stabillizer bar x Axle carrier2526019
PS pressure hose x PS pump5657542
Rear TWC x Center pipe4040029
Center pipe x Tailpipe4040029
Heated oxygen sensor (Bank 1 sensor 1) x Front exhaust pipe2020014
Heated oxygen sensor (Bank 1 sensor 2) x Center pipe2020014
No. 2 support bracket x Frame18.518513
No. 3 support bracket x Frame18.518513
No. 4 support bracket x Frame18.518513
Exhaust pipe damper x Tailpipe19.519514
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SS1EQ−01
−
SERVICE SPECIFICATIONS EMISSION CONTROL
SS−9
132
Author: Date:
1996 LAND CRUISER (RM451U)
EMISSION CONTROL
SERVICE DATA
VSV for EVAPResistance at 20°C (68° F)30 − 34 Ω
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