engine coolant TOYOTA LAND CRUISER 1996 J80 Repair Manual

EM1E3−01
EM−28
−
ENGINE MECHANICAL CYLINDER HEAD
1996 LAND CRUISER (RM451U)
REMOVAL
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 AIR CLEANER HOSE AND CAP
4. DISCONNECT CRUISE CONTROL ACTUATOR CABLE FROM THROTTLE BODY
5. DISCONNECT ACCELERATOR CABLE FROM
THROTTLE BODY
6. DISCONNECT THROTTLE CABLE FROM THROTTLE BODY
7. DISCONNECT ENGINE GROUND STRAPS
(a) Disconnect the ground strap from the No. 1 engine hang-
er.
(b) Disconnect the ground strap from the air intake chamber.
8. DISCONNECT CONNECTOR ON INTAKE MANIFOLD FROM LH FENDER APRON
9. DISCONNECT BRAKE BOOSTER VACUUM HOSE
10. DISCONNECT EVAP HOSE
11. DISCONNECT FUEL RETURN HOSE
12. DISCONNECT HEATER HOSES
13. 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 )
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EM−64
−
ENGINE MECHANICAL CYLINDER HEAD
1996 LAND CRUISER (RM451U)
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
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EM1ED−02
−
ENGINE MECHANICAL ENGINE UNIT
EM−69
1996 LAND CRUISER (RM451U)
REMOVAL
1. DRAIN ENGINE COOLANT
2. DRAIN ENGINE OIL
3. REMOVE HOOD
4. 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.
5. REMOVE RADIATOR GRILLE
Remove the 5 screws, clip and radiator grille.
6. REMOVE RADIATOR (See page CO−14 )
7. DISCONNECT OIL COOLER HOSE FROM OIL COOL- ER 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
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−
ENGINE MECHANICAL ENGINE UNIT
EM−81
1996 LAND CRUISER (RM451U)
26. CONNECT EVAP HOSE
27. CONNECT BRAKE BOOSTER VACUUM HOSE
28. 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 LEV-
ELS
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LU0KG−02
−
LUBRICATION OIL PUMP
LU−5
1996 LAND CRUISER (RM451U)
REMOVAL
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. DISCONNECT A/C COMPRESSOR AND BRACKET
(a) Loosen the idler pulley nut and adjusting bolt, and remove
the drive belt.
(b) Remove the 4 mounting bolts, and disconnect the com- pressor from the bracket.
HINT:
Put aside the compressor, and suspend it.
(c) Remove the 5 bolts and A/C compressor bracket.
6. REMOVE RADIATOR PIPE
(a) Disconnect the No.2 radiator hose from the water inlet.
(b) 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
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LU0KK−02
LU−16
−
LUBRICATION OIL COOLER
1996 LAND CRUISER (RM451U)
REMOVAL
1. DRAIN ENGINE COOLANT
2. REMOVE AIR CLEANER CAP AND HOSE
3. REMOVE FRONT EXHAUST PIPE
(a) Disconnect the heated oxygen sensor connector.
(b) Remove the 2 nuts and 2 bolts holding the front exhaust pipe to the rear TWC.
(c) Disconnect the front exhaust pipe, and remove the gas- ket.
(d) Loosen the clamp bolt and disconnect the clamp from the
No.1 support bracket.
(e) Remove the 2 bolts and No.1 support bracket.
(f) Remove the 4 nuts, front exhaust pipe and 2 gaskets.
4. REMOVE NO.1 EXHAUST MANIFOLD
(a) Remove the 3 bolts and No.1 heat insulator.
(b) Remove the 6 nuts, exhaust manifold and gasket.
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LU08Z−04
P08343
Adhesive
−
LUBRICATION OIL COOLER
LU−19
1996 LAND CRUISER (RM451U)
INSTALLATION
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. INSTALL OIL PRESSURE SWITCH
(a) Apply adhesive to 2 or 3 threads of the oil pressure switch.
Adhesive:
Part No. 08833 −00080, THREE BOND 1344,
LOCTITE 242 or equivalent
(b) Install the oil pressure switch.
5. INSTALL NO.1 EXHAUST MANIFOLD
(a) Install a new gasket and the exhaust manifold with the 6 nuts.
Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)
(b) Install the heat insulator with the 3 bolts. Torque: 19 N·m (195 kgf·cm, 14 ft·lbf)
6. 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)
7. INSTALL AIR CLEANER CAP AND HOSE
8. FILL RADIATOR WITH ENGINE COOLANT
9. START ENGINE AND CHECK FOR LEAKS
10. CHECK ENGINE OIL
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MA02R−04
MA−4
−
MAINTENANCE UNDER HOOD
44
Author: Date:
1996 LAND CRUISER (RM451U)
UNDER HOOD
GENERAL MAINTENANCE
1. GENERAL NOTICE
Maintenance items may vary from country to country. Check the owner’s manual supplement in which
the maintenance schedule is shown.
Every service item in the periodic maintenance schedule must be performe\
d.
Periodic maintenance service must be performed according to whichever interval in\
the periodic main-
tenance schedule occurs first, the odometer reading (miles) or the time inter\
val (months).
Maintenance service after the last period should be performed at the same interval \
as before unless
otherwise noted.
Failure to do even one item can cause the engine to run poorly and incre\
ase 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 se\
e −through reservoir.
4. RADIATOR AND HOSES
(a) Check that the front of the radiator is clean and not blocked with leave\
s, 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 upp\
er 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 temp\
erature.
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 sel\
ector 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.
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MA04U−01
P04771
−
MAINTENANCE ENGINE
MA−5
45
Author: Date:
1996 LAND CRUISER (RM451U)
ENGINE
INSPECTION
HINT:
Inspect these items when the engine is cold.
1. INSPECT DRIVE BELT (See page CH−2)
2. INSPECT AIR FILTER
(a) Visually check that the air cleaner element is not exces- sively 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 p ipes, hangers and connections for severe
corrosion, leaks or damage.
11. ADJUST VALVE CLEARANCE (See page EM−4)
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PP30C−03
−
PREPARATION COOLING
PP−15
1996 LAND CRUISER (RM451U)
COOLANT
ItemCapacityClassification
Engine coolant
w/ Front heater
w/ Front heater and rear heaters
12.5 liters (13.2 US qts, 11.1 lmp. qts)
13.4 liters (14.2 US qts, 11.8 lmp. qts)
Ethylene−glycol base
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