TOYOTA LAND CRUISER 1996 J80 Workshop Manual

LU0KI−02
LU−12
−
LUBRICATION OIL PUMP
1996 LAND CRUISER (RM451U)
INSTALLATION
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.
Using a razor blade and gasket scraper, remove all
the old packing (FIPG) material from the gasket sur-
faces and sealing grooves.
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 No.1 oil pan as shown in the il- lustration.
Seal packing: Part No. 08826−00080 or equivalent
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.
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.
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−
LUBRICATION OIL PUMP
LU−13
1996 LAND CRUISER (RM451U)
(c) Install a new gasket in position.
(d) Pour in approximately 15 cm
3 (0.9 cu in.) of engine oil into
oil pump hole.
(e) 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)
9. INSTALL NO.2 OIL PAN
(a) Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surface of the No.1 oil
pan.
Using a razor blade and gasket scraper, remove all
the old packing (FIPG) material from the gasket sur-
faces and sealing grooves.
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 No.2 oil pan as shown in the il- lustration.
NOTICE:
Do not use a solvent which will affect the painted surfaces. 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 or 3 − 4 mm (0.012 − 0.016 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 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 BOL TS HOLDING NO.1 OIL PAN TO TRANS-
MISSION HOUSING
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LU−14
−
LUBRICATION OIL PUMP
1996 LAND CRUISER (RM451U)
Install the 6 bolts.
Torque: 72 N·m (730 kgf·cm, 53 ft·lbf)
11. INSTALL OIL LEVEL SENSOR
(a) Install a new gasket to the level sensor.
(b) 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
PA N
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
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LU08W−03
−
LUBRICATION OIL COOLER
LU−15
726
Author: Date:
1996 LAND CRUISER (RM451U)
OIL COOLER
COMPONENTS
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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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−
LUBRICATION OIL COOLER
LU−17
1996 LAND CRUISER (RM451U)
5. REMOVE OIL PRESSURE SWITCH
6. REMOVE OIL COOLER AND OIL COOLER COVER AS-
SEMBLY
Remove the 10 bolts, 2 nuts, oil cooler and oil cooler cover as-
sembly 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.
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LU08Y−03
LU−18
−
LUBRICATION OIL COOLER
1996 LAND CRUISER (RM451U)
INSPECTION
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.
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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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LU0KL−01
LU−20
−
LUBRICATION OIL NOZZLE
731
Author: Date:
1996 LAND CRUISER (RM451U)
OIL NOZZLE
COMPONENTS
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LU0KM−04
−
LUBRICATION OIL NOZZLE
LU−21
1996 LAND CRUISER (RM451U)
REMOVAL
1. REMOVE CYLINDER HEAD (See page EM−28 )
2. 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.
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