TOYOTA LAND CRUISER 1996 J80 Workshop Manual

EC0JT−01
−
EMISSION CONTROL EXHAUST GAS RECIRCULATION (EGR) SYSTEM
EC−11
1996 LAND CRUISER (RM451U)
INSPECTION
1. INSPECT AND CLEAN FILTER IN EGR V ACUUM MOD-
ULATOR
(a) Remove the cap and filter.
(b) Check the filter for contamination or damage.
(c) Using compressed air, clean the filter.
(d) Reinstall the filter and cap.
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. INSPECT OPERATION OF VSV AND EGR VACUUM
MODULATOR WITH HOT ENGINE
(a) Warm up the engine to above 53° C (127°F).
(b) Check that the vacuum gauge indicates low vacuum at 2,500 rpm.
(c) Disconnect the vacuum hose port R of the EGR vacuum modulator and connect port R directly to the air intake
chamber with another hose.
(d) Check that the vacuum gauge indicates high vacuum at 2,500 rpm.
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EC−12
−
EMISSION CONTROL EXHAUST GAS RECIRCULATION (EGR) SYSTEM
1996 LAND CRUISER (RM451U)
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. INSPECT EGR VALVE
(a) 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.
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(a)
(b)
(c)
−
EMISSION CONTROL EXHAUST GAS RECIRCULATION (EGR) SYSTEM
EC−13
1996 LAND CRUISER (RM451U)
15. INSPECT VSV OPERATION
(a) 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. DISCONNECT V ACUUM HOSES FROM EGR V ACUUM
MODULATOR
(a) Disconnect the vacuum hose from R port.
(b) Disconnect the vacuum hose from Q port.
(c) Disconnect the vacuum hose from P port.
19. INSPECT EGR VACUUM MODULATOR OPERATION
(a) Block ports P and R with your finger.
(b) Blow air into port Q, and 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 resis-
tance to air flow.
If operation is not as specified, replace the EGR vacuum modu-
lator.
20. RECONNECT VACUUM HOSES TO EGR VACUUM
MODULATOR
(a) Connect the vacuum hose to R port.
(b) Connect the vacuum hose to Q port.
(c) Connect the vacuum hose to P port.
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EC−14
−
EMISSION CONTROL EXHAUST GAS RECIRCULATION (EGR) SYSTEM
1996 LAND CRUISER (RM451U)
21. REMOVE EGR VACUUM MODULATOR
22. REMOVE EGR VALVE
(a) Disconnect the vacuum hose from the EGR valve.
(b) Disconnect the engine wire from the clamp.
(c) Loosen the EGR pipe union nut.
(d) 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)
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EC0H3−02
−
EMISSION CONTROL THREE−WAY CATALYTIC CONVERTER (TWC)
SYSTEMEC−15
628
Author: Date:
1996 LAND CRUISER (RM451U)
THREE−WAY CATALYTIC CONVERTER (TWC) SYSTEM
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−11 0 )
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EM1E0−04
−
ENGINE MECHANICAL CO/HC
EM−1
504
Author: Date:
1996 LAND CRUISER (RM451U)
CO/HC
INSPECTION
HINT:
This check is used only to det ermine 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 SE-
CONDS
4. 4.INSERT CO/HC METER TESTING PROBE AT LEAST
40 cm (1.3 ft) INTO TAILPIPE DURING IDLING
5. 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 regula-
tions.
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EM−2
−
ENGINE MECHANICAL CO/HC
505
Author: Date:
1996 LAND CRUISER (RM451U)
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.
COHCProblemsCauses
NormalHighRough idle
3. Faulty ignitions:
Incorrect timing
 Fouled, shorted or improperly gapped plugs
 Open or crossed high −tension cords
 Cracked distributor cap
4. Incorrect valve clearance
5. Leaky EGR valve
6. Leaky intake and exhaust valves
7. Leaky cylinders
LowHighRough idle
(Fluctuating HC reading)
1. Vacuum leaks:
 PCV hose
 EGR valve
 Intake manifold
 Air intake chamber
 Throttle body
 IAC valve
 Brake booster line
2. Lean mixture causing misfire
HighHighRough idle
(Black smoke from exhaust)
1. Restricted air filter
2. Faulty SFI systems:
 Faulty pressure regulator
 Clogged fuel return line
 Defective ECT sensor
 Faulty ECM
 Faulty injector
 Faulty throttle position sensor
 Faulty MAF meter
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EM0KR−04
−
ENGINE MECHANICAL COMPRESSION
EM−3
506
Author: Date:
1996 LAND CRUISER (RM451U)
COMPRESSION
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. CHECK CYLINDER COMPRESSION PRESSURE
(a) Insert a compression gauge into the spark plug hole.
(b) Fully open the throttle.
(c) 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 pos-
sible. Compression pressure:
1,176 kPa (12.0 kgf/cm
2, 171 psi) or more
Minimum pressure: 883 kPa (9.0 kgf/cm
2, 128 psi)
Difference between each cylinder:
98 kPa (1.0 kgf/cm
2, 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.
If adding oil helps the compression, it is likely that
the piston rings and/or cylinder bore are worn or
damaged.
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
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EM1Q4−01
P05120A16078
1 Dot Mark
EM−4
−
ENGINE MECHANICAL VALVE CLEARANCE
507
Author: Date:
1996 LAND CRUISER (RM451U)
VALVE CLEARANCE
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. DISCONNECT ENGINE WIRE AND HEATER VALVE FROM COWL PANEL
(a) Remove the 2 bolts and disc onnect the ground strap and
engine wire.
(b) Remove the 2 bolts and disconnect the heater valve.
4. DISCONNECT HIGH −TENSION CORDS FROM SPARK
PLUGS (See page IG−1 )
5. REMOVE CYLINDER HEAD COVER
Remove the 13 bolts, cylinder head cover and gasket.
6. SET NO. 1 CYLINDER TO TDC/COMPRESSION
(a) 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.
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−
ENGINE MECHANICAL VALVE CLEARANCE
EM−5
508
Author: Date:
1996 LAND CRUISER (RM451U)
7. INSPECT VALVE CLEARANCE
(a) Check only the valves indicated.
Using a thickness gauge, measure the clearance
between the valve lifter and camshaft.
Record the out−of−specification valve clearance
measurements. They will be used later to determine
the required replacement adjusting shim.
Valve clearance (Cold):
Intake0.15 − 0.25 mm (0.006 − 0.010 in.)
Exhaust0.25 − 0.35 mm (0.010 − 0.041 in.)
(b) Turn the crankshaft pulley 1 revolution (360 °) and align
the its groove with timing mark ”0” of the timing chain cov-
er.
(c) Check only the valves 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
(a) Remove the adjusting shim.
Turn the crankshaft to position the cam lobe of the
camshaft on the adjusting valve upward.
Position the notch of the valve lifter toward the spark
plug side.
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