TOYOTA LAND CRUISER 1996 J80 Workshop Manual

EM−106
−
ENGINE MECHANICAL CYLINDER BLOCK
1996 LAND CRUISER (RM451U)
(2) Install the 7 main bearing caps in their proper loca-
tions.
HINT:
Each bearing cap has a number and front mark.
(b) Install the main bearing cap bolts.
HINT:
The main bearing cap bolts are tightened in 2 progressive
steps (steps (b) and (d)).
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) Mark the front of the main bearing cap bolt withpaint.
(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.
(c) Check that the crankshaft turns smoothly.
(d) Check that the crankshaft thrust clearance (See page EM−83 ).
10. INSTALL PISTON AND CONNECTING ROD AS- SEMBLIES
(a) Cover the connecting rod bolts with a short piece of hose
to protect the crankshaft from damage.
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−
ENGINE MECHANICAL CYLINDER BLOCK
EM−107
1996 LAND CRUISER (RM451U)
(b) Using a piston ring compressor, push the correctly num-
bered piston and connecting rod assemblies into each
cylinder with the front mark of the piston facing forward.
11. INSTALL CONNECTING ROD CAP
(a) Place the connecting rod cap on the connecting rod. (1) Match the numbered connecting rod cap with theconnecting rod.
(2) Install the connecting rod cap with the front mark facing for ward.
(b) Install the connecting rod cap nuts.
HINT:
The connecting rod cap nuts are tightened in 2 progres-
sive steps (steps (b) and (d)).
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 con-
necting 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) Mark the front of the connecting rod cap nut and bolt
with paint.
(4) Retighten the connecting rod cap nuts 90 ° as
shown.
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P04615
EM−108
−
ENGINE MECHANICAL CYLINDER BLOCK
1996 LAND CRUISER (RM451U)
(5) Check that the painted mark on the nut is at 90 °
angle in relation to the mark on the bolt.
(c) Check that the crankshaft turns smoothly.
(d) Check that the connecting rod thrust clearance (See page
EM−83 ).
12. INSTALL REAR OIL SEAL RETAINER
(a) Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the retainer
and cylinder block.
Using a razor blade and gasket scraper, remove all
the old packing (FIPG) material from the gasket sur-
faces and sealing groove.
Thoroughly clean all components to remove all the
loose material.
Using a non −residue solvent, clean both sealing
surfaces.
(b) Apply seal packing to the retainer as shown in the illustra-
tion.
Seal packing: Part No. 08826−00080 or equivalent
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.
Parts must be assembled within 5 minutes of ap-
plication. Otherwise the material must be removed
and reapplied.
Immediately remove nozzle from the tube and rein-
stall 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)
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ENGINE MECHANICAL CYLINDER BLOCK
EM−109
1996 LAND CRUISER (RM451U)
14. INSTALL LH ENGINE MOUNTING BRACKET
(a) Install the bracket with the 4 bolts.
Torque: 69 N·m (700 kgf·cm, 51 ft·lbf)
(b) Install the insulator with the nut. Torque: 72 N·m (730 kgf·cm, 43 ft·lbf)
15. INSTALL RH ENGINE MOUNTING BRACKET
(a) Install the bracket with the 4 bolts. Torque: 69 N·m (700 kgf·cm, 51 ft·lbf)
(b) Install the insulator with the nut. Torque: 72 N·m (730 kgf·cm, 43 ft·lbf)
16. INSTALL PS PUMP
(a) Place a new O−ring to the pump.
(b) 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)
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EM0EE−10
EM−11 0
−
ENGINE MECHANICAL EXHAUST SYSTEM
613
Author: Date:
1996 LAND CRUISER (RM451U)
EXHAUST SYSTEM
COMPONENTS
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IG0IB−02
SPARK TEST
TRY ANOTHER IGNITERNO
OK
OK
OK
OK
OK
BAD
BAD
BAD
BAD
BAD
BADConnect securely.
Replace the cord(s).
Replace the distributor housing assembly.
Check wiring between ECM, ignition coil and
igniter, and then try another ECM.
CHECK CONNECTION OF IGNITION COIL, IGNITER AND
DISTRIBUTOR CONNECTOR
CHECK RESISTANCE OF HIGH−
TENSION CORD
(See step 8)
Maximum resistance: 25 k Ω per cord
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
CHECK AIR GAP OF DISTRIBUTOR (See step 31)
Air gap: 0.2 − 0.4 mm (0.008 −0.016 in.)
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
CHECK IGT SIGNAL FROM ECM
(See page DI−93 ) Check
wiring between ignition switch to ignition
coil and igniter.
Replace the ignition coil.
Replace the distributor housing assembly.
BAD
OK
CHECK
POWER SUPPLY TO IGNITION COIL AND IGNITER
1. Turn ignition switch to ON.
2. Check that there is battery voltage at ignition coil positive (+)
terminal.
−
IGNITION IGNITION SYSTEM
IG−1
735
Author: Date:
1996 LAND CRUISER (RM451U)
IGNITION SYSTEM
ON−VEHICLE INSPECTION
1. CHECK THAT SPARK OCCURS
(a) Disconnect the high −tension cords (from the ignition coil)
from the distributor cap.
(b) Hold the end approx. 12.5 mm (0.50 in.) from the body ground.
(c) Check if spark occurs while engine is being cranked.
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:
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P22687
P08512
IG−2
−
IGNITION IGNITION SYSTEM
736
Author: Date:
1996 LAND CRUISER (RM451U)
2. REMOVE NO.2 PCV HOSE
3. REMOVE AIR CLEANER HOSE
4. DISCONNECT THROTTLE CABLE
5. REMOVE NO.2 AND NO.3 CYLINDER HEAD COVERS
Remove the 4 bolts and head covers.
6. DISCONNECT HIGH −TENSION CORDS FROM SPARK
PLUGS
(a) Remove the 2 mounting bolts of the No.1 and No.2 cord clamps.
(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.
7. DISCONNECT HIGH−TENSION CORDS FROM DIS- TRIBUTOR CAP AND IGNITION COIL
(a) Using a screwdriver, lift up the lock claw and disconnect
the holder from the distributor cap (ignition coil).
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−
IGNITION IGNITION SYSTEM
IG−3
737
Author: Date:
1996 LAND CRUISER (RM451U)
(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 k Ω per cord
If the resistance is greater than maximum, check the terminals.
If necessary, replace the high −tension cord.
9. RECONNECT HIGH− TENSION CORDS TO DISTRIBU-
TOR CAP AND IGNITION COIL
(a) 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.
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IG−4
−
IGNITION IGNITION SYSTEM
738
Author: Date:
1996 LAND CRUISER (RM451U)
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
(a) Secure the high −tension cords with the cord clamps as
shown in the illustration.
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IG0152
P03783
−
IGNITION IGNITION SYSTEM
IG−5
739
Author: Date:
1996 LAND CRUISER (RM451U)
(b) 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.
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
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