width TOYOTA LAND CRUISER 1996 J80 Workshop Manual

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INTRODUCTION TERMS
IN−35
35
Author: Date:
1996 LAND CRUISER (RM451U)
H/B
Hatchback
H−FUSEHigh Current Fuse
HIHigh
HIDHigh Intensity Discharge (Head Lamp)
HPUHydraulic Power Unit
HSGHousing
HTHard Top
HWSHeated Windshield System
IACIdle Air Control
ICIntegrated circuit
IDIIndirect Diesel Injection
IFSIndependent Front Suspension
IGIgnition
IIAIntegrated Ignition Assembly
INIntake (Manifold, V
alve)
INTIntermittent
I/PInstrument Panel
IRSIndependent Rear Suspension
J/BJunction Block
J/CJunction Connector
KDKick−Down
LANLocal Area Network
LBLiftback
LCDLiquid Crystal Display
LEDLight Emitting Diode
LHLeft−Hand
LHDLeft−Hand Drive
L/H/WLength, Height, Width
LLCLong− Life Coolant
LNGLiquified Natural Gas
LOLow
LPGLiquified Petroleum Gas
LSDLimited Slip Dif ferential
LSP & PVLoad Sensing Proportioning And Bypass V alve
LSPVLoad Sensing Proportioning Valve
MAX.Maximum
M−FUSEMedium Current Fuse
MICMicrophone
MILMalfunction Indicator Lamp
MIN.Minimum
MPMultipurpose
MPXMultiplex Communication System
M/TManual Transmission (T ransaxle)
MTMount
MTGMounting
NNeutral
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N09214
DI−4
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DIAGNOSTICS ENGINE
1996 LAND CRUISER (RM451U)
The diagnosis system operates in normal mode
during normal vehicle use. It also has a check mode
for technicians to simulate malfunction symptoms
and troubleshoot. Most DTC use 2 trip detection
logic* to prevent erroneous detection, and ensure
thorough malfunction detection. By switching the
ECM to check mode when troubleshooting, the
technician can cause the MIL to light up for a mal-
function that is only detected once or momentarily
(TOYOTA hand−held tester only) (See step 2).
*2 trip detection logic:
When a logic malfunction is first detected, the mal-
function is temporarily stored in the ECM memory.
If the same malfunction is detected again during the
second drive test, this second detection causes the
MIL to light up.
The 2 trip repeats the same mode a 2nd time (How-
ever, the IG switch must be turned OFF between the
1st trip and 2nd trip.).
Freeze frame data:
Freeze frame data records the engine condition
when a misfire (DTC P0300 − P0306) or fuel trim
malfunction (DTC P0171, P0172) or other malfunc-
tion (first malfunction only), is detected.
Because freeze frame data records the engine
conditions (fuel system, calculator load, engine
coolant temperature, fuel trim, engine speed, ve-
hicle speed, etc.) when the malfunction is detected,
when troubleshooting it is useful for determining
whether the vehicle was running or stopped, the en-
gine warmed up or not, the air− fuel ratio lean or rich,
etc. at the time of the malfunction.
Priorities for troubleshooting:
If troubleshooting priorities for multiple DTCs are given in the
applicable diagnostic chart, these should be followed.
If no instructions are given troubleshoot DTCs according to the
following priorities. (1) DTC other than fuel trim malfunction (DTC P0171,
P0172), EGR (DTC P0401, P0402), and misfire
(DTC P0300 − P0306).
(2) Fuel trim malfunction (DTC P0171, P0172), and EGR (DTC P0401, P0402).
(3) Misfire (DTC P0300 − P0306).
(b) Check the DLC3. The vehicle’s ECM uses V.P.W. (V ariable Pulse Width) for
communication to comply with SAE J1850. The terminal
arrangement of DLC3 complies with SAE J1962 and
matches the V.P.W. format.
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P22475
BatteryFusible
Link
FL AM2
F7W−R
EA2
W−R
B−R B−R
EA2
B−R
B−W B−W
W−B
Distributor
Ignition
Coil 4
12
EA2
IH1
W−B
8 1
2
Noise
Filter 45
B 3
Igniter Tr2
2
1
IH2 IH2
B−G
B−G
B−Y B−YE4
E4 IGT
IGF Tr15V
ECM
1 3 11
6
IG Switch
1
EC
17 23
14 13
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DIAGNOSTICS ENGINE
DI−97
1996 LAND CRUISER (RM451U)
DTC P1300 Igniter Circuit Malfunction
CIRCUIT DESCRIPTION
The ECM determines the ignition timing, turns on Tr1 at a predetermined angle ( °CA) before the desired
ignition timing and outputs and ignition signal (IGT) ”1” to the\
igniter.
Since the width of the IGT signal is constant, the dwell angle control circuit in \
the igniter determines the time
the control circuit starts primary current flow to the ignition coil based \
on the engine rpm and ignition timing
one revolution ago, that is, the time the Tr2 turns on.
When it reaches the ignition timing, the ECM turns Tr1 off and outputs the IGT signal ”O”.
This turns Tr2 off, interrupting the primary current flow and generating a high voltage i\
n the secondary coil
which causes the spark plug to spark. Also, by the counter electromotive forc\
e generated when the primary
current is interrupted, the igniter sends an ignition confirmation signal (IGF)\
to the ECM. The ECM stops fuel
injection as a fail safe function when the IGF signal is not input to the ECM.
DTC No.DTC Detecting ConditionTrouble Area
P1300No IGF signal to ECM for 6 consecutive IGT signals during
engine running Open or short in IGF or IGT circuit from igniter to ECM
 Igniter
 ECM
WIRING DIAGRAM
DI5PQ−02
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N09214
DLC3
DI−134
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DIAGNOSTICS AUTOMATIC TRANSMISSION
1996 LAND CRUISER (RM451U)
(9) After simulating the malfunction conditions, use the
TOYOTA hand−held tester diagnosis selector to
check the DTCs and freeze frame data, etc.
HINT:
Take care not to turn the ignition switch OFF. T urning the ignition
switch off switches the diagnosis system from check mode to
normal mode, so all DTCs, etc. are erased. (10) After checking the DTC, inspect the applicable cir-cuit.
(b) Clear the DTC. The following actions will erase the DTCs and freeze
frame data.Operating the OBD II scan tool (complying with SAE
J1978) or TOYOTA hand−held tester to erase the
codes (See the OBD II scan tool’s instruction book
for operating instructions.).
NOTICE:
If the T OYOTA hand−held tester switches the ECM from the
normal mode to the check mode or vice−versa, or if the
ignition switch is turned from ON to ACC or OFF during the
check mode, the DTCs and freezed frame data will be
erased.
(c) Check the DLC3. The vehicle’s ECM uses V.P.W. (V ariable Pulse Width) for
communication to comply with SAE J1850. The terminal
arrangement of DLC3 complies with SAE J1962 and
matches the V.P.W. format.
Terminal No.Connection/V oltage or ResistanceCondition
2Bus  Line/Pulse generationDuring communication
4Chassis Ground − Body/1 Ω or lessAlways
5Signal Ground − Body/1 Ω or lessAlways
16Battery Positive − Body/9 − 14 V or 1 Ω or lessAlways
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P03849
Overall Length
EM0255
P04415
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ENGINE MECHANICAL CYLINDER HEAD
EM−43
1996 LAND CRUISER (RM451U)
(d) Check the valve overall length.
Standard overall length:
Intake98.4 mm (3.874 in.)
Exhaust97.4 mm (3.854 in.)
Minimum overall length:
Intake97.9 mm (3.854 in.)
Exhaust97.4 mm (3.835 in.)
If the overall length is less than minimum, replace the valve.
(e) Check the surface of the valve stem tip for wear.
If the valve stem tip is worn, resurface the tip with a grinder or
replace the valve.
NOTICE:
Do not grind off more than minimum.
7. INSPECT AND CLEAN VALVE SEATS
(a) Using a 45° carbide cutter, resurface the valve seats.
Remove only enough metal to clean the seats.
(b) Check the valve seating position. Apply a light coat of prussian blue (or white lead) to the
valve face. Lightly press the valve against the seat. Do not
rotate valve.
(c) Check the valve face and seat for the following:
If blue appears 360 ° around the face, the valve is
concentric. If not, replace the valve.
If blue appears 360 ° around the valve seat, the
guide and face are concentric. If not, resurface the
seat.
Check that the seat contact is in the middle of the
valve face with these width:
Intake1.2 − 1.6 mm (0.047 − 0.063 in.)
Exhaust1.0 − 1.4 mm (0.039 − 0.055 in.)
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PP2YQ−02
PP−64
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PREPARATION SUPPLEMENTAL RESTRAINT SYSTEM
1996 LAND CRUISER (RM451U)
EQUIPMENT
Bolt
Length: 35 mm (1.38 in.)
Pitch: 1.0 mm (0.039 in.)
Diam: 6.0 mm (0.236 in.)Airbag disposal
Rope (no projections, difficult to break)Airbag disposal
Tire
Width: 185 mm (7.28 in.)
Inner diam: 360 mm (14.17 in.)Airbag disposal
Tire with disc wheel
Width: 185 mm (7.28 in.)
Inner diam: 360 mm (14.17 in.)Airbag disposal
Torque wrenchSteering wheel pad
Vinyl bagAirbag disposal
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Z04247
ColorDrit Mark
Bearing Cup
Drit Mark
Yoke
Q07142
Type A Type B X
610.0 mm (24.016 in.)
Y
545.0 mm (21.457 in.)
X
Y Differential
Side
Z00755
PR0081
Q07338
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PROPELLER SHAFT SPIDER BEARING
PR−7
855
Author: Date:
1996 LAND CRUISER (RM451U)
5. SELECT SPIDER BEARING
Select the bearing according to whether or not there is a drill
mark on the yoke section.
YokeBearing (T ype A)Bearing (Type B)
w/ drill markw/ color mark (White)w/ color mark (Red)
No drill markNo color markNo color mark
HINT:
At time of the reassemble, there are 2 types of rear propeller
shafts, type A and type B. Referring to the illustration, measure
the distance between the welding points X and Y to identify
which of the 2 types is used for the vehicle.
6. INSTALL SPIDER BEARING
(a) Apply MP grease to a new spider and bearings.
NOTICE:
Be careful not to apply too much grease.
(b) Align the matchmarks on the yoke and flange.
(c) Fit the spider into the yoke.
(d) Using SST, install the bearings on the spider. SST 09332−25010
(e) Using SST, adjust both bearings so that the snap ring grooves are at maximum and equal widths.
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R11852Weight
R04211
Inner Diam
Tires
(3 or More) Width
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SUPPLEMENTAL RESTRAINT SYSTEM STEERING WHEEL PAD AND SPIRAL CABLE
RS−17
1996 LAND CRUISER (RM451U)
(f) Cover the steering wheel pad with a cardboard box or
tires.
Covering method using a cardboard box:
Cover the steering wheel pad with the cardboard
box and weight the cardboard box down in 4 places
with at least 190 N (20 kg, 44 lb).
Size of cardboard box:
Must exceed the following dimensions:
x=460 mm (18.11 in.)
When dimension of the cardboard box exceeds the di-
ameter of the disc wheel with tire to which the steer-
ing wheel pad is tied
x=460 mm (18.11 in.) + width of tire
y= 650 mm (25.59 in.)
NOTICE:
If a cardboard box smaller than the specified size is used,
the cardboard box will be broken by the shock from the air-
bag deployment.
Covering method using tires:
Place at least 3 ti res without disc wheel on top of the
disc wheel with tire to which the steering wheel pad
is tied.
Tire size: Must exceed the following dimensions −
Width: 185 mm (7.87 in.)
Inner diameter: 360 mm (14.17 in.)
CAUTION:
Do not use tires with disc wheels.
NOTICE:
The tires may be marked by the airbag deployment, so use
the redundant tires.
(g) Deploy the airbag. (1) Connect the SST red clip to the battery positive (+)
terminal and the black clip to the battery negative
(−) terminal.
(2) Check that no one is within 10 m (33 ft) area around
the disc wheel which the steering wheel pad is tied
to.
(3) Press the SST activation switch and deploy the air- bag.
HINT:
The airbag deploys simultaneously as the LED of the SST ac-
tivation switch lights up.
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R11891
WidthInner
Diam.
AB0158
Battery
SST
R09689
Tires
(5 or more)
RS−28
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SUPPLEMENTAL RESTRAINT SYSTEM FRONT PASSENGER AIRBAG ASSEMBLY
1996 LAND CRUISER (RM451U)
CAUTION:
If the front passenger airbag assembly is tied down with
too thin wire harness, it may snap. This is highly danger-
ous. Always use a wire harness which is at least 1.25 mm
2
(0.0019 in.2)
(1) Wind the wire harness around the tire, passing the wire harness through the installation holes indi-
cated by arrows in the illustration.
(2) Position the front passenger airbag assembly in- side the tire with the airbag deployment side facing
inside.
Tire size: Must exceed the following dimensions −
Width: 185 mm (7.28 in.)
Inner diameter: 360 mm (14.17 in.)
CAUTION:
Make sure that the wire harness is tight. It is very dan-
gerous if looseness in the wire harness results in the
front passenger airbag assembly coming free due to
the shock from the airbag deploying.
Always tie down the front passenger airbag assembly
with the airbag deployment side facing inside.
NOTICE:
The tire will be marked by the airbag deployment, so use a
redundant tire.
(c) Check functioning of the SST. SST 09082−00700
(d) Place tires. (1) Place at least 2 tires under the tire to which the frontpassenger airbag assembly is tied.
(2) Place at least 2 tires over the tire to which the front passenger airbag assembly is tied. The top tire
should have the wheel installed.
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SA2417
Holes
Groore
Z15179
FIPG Width Approx.
1 − 2 mm (0.04 − 0.08 in.)
Z10101
Adhesive
SA2205
SA1979Lock
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SUSPENSION AND AXLE FRONT DIFFERENTIAL CARRIER
SA−45
1996 LAND CRUISER (RM451U)
30. w/ DIFFERENTIAL LOCK:
INSTALL SHIFT FORK SHAFT
(a) Apply MP grease onto the outer circuit of the fork shaft.
(b) Install the fork shaft to match the hole of the shift fork and
that of the shift fork shaft.
(c) Remove any FIPG material and be careful not to drop oil on the contacting surface of the differential carrier and
shaft retainer.
(d) Apply FIPG to the carrier, as shown. FIPG: Part No. 08826−00090, THREE BOND 1281 or
equivalent
HINT:
Install the shaft retainer within 10 minutes after applying FIPG.
(e) Clean the threads of the bolts and retainer bolts holes with
toluene or trichlorethylene.
(f) Apply adhesive to 2 or 3 threads of the mount bolt end. Adhesive: Part No. 08833 −00080, THREE BOND 1344,
LOCTITE 242 or equivalent
(g) Tighten the shaft retainer with the 2 bolts. Torque: 24 N·m (240 kgf·cm, 17 ft·lbf)
(h) Using a pin punch and hummer, install the slotted spring pin to the shift fork.
(i) Shift the fork deeply and keep the differential lock condi- tion.
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