control TOYOTA LAND CRUISER 1996 J80 Workshop Manual

EM−78
−
ENGINE MECHANICAL ENGINE UNIT
1996 LAND CRUISER (RM451U)
15. INSTALL TRANSFER SHIFT LEVER
(a) Install the shift lever and hose clamp with the 4 bolts.
Torque: 18 N·m (185 kgf·cm, 13 ft·lbf)
(b) Connect the shift rod and install the pin.
(c) Install the transfer shift lever boot and transmission shift lever assembly with the 10 bolts.
Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf)
(d) Connect the 3 connectors to the transmission shift lever assembly.
(e) Install the console box with the 3 bolts.
(f) Connect the pattern select switch connector.
(g) Install the console with the 4 screws.
(h) Install the transfer shift lever knob.
(i) Shift the shift lever to N position.
(j) Fully turn the control shaft lever back and return 2 notches. It is now in neutral position.
(k) Connect the transmission control rod with the nut.
Torque: 13 N·m (130 kgf·cm, 9 ft·lbf)
Brought to you by BirfMark
Brought to you by BirfMark
Version 1.11 - 03/16/2010

−
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
Brought to you by BirfMark
Brought to you by BirfMark
Version 1.11 - 03/16/2010

MA02Q−04
MA−2
−
MAINTENANCE INSIDE VEHICLE
42
Author: Date:
1996 LAND CRUISER (RM451U)
INSIDE VEHICLE
GENERAL MAINTENANCE
The owners are responsible for these maintenance and inspection items.
They can be done by the owner or they can have them done at a service sh\
op.
These items include those which should be checked on a daily basis, thos\
e which, in most cases, do not
require (special) tools and those which are considered to be reasonabl\
e for the owner to do.
Items and procedures for general maintenance are as follows.
1. GENERAL NOTES
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. LIGHTS
(a) Check that the headlights, stop lights, taillights, turn signal lights, \
and other lights are all working.
(b) Check the headlights aim.
3. WARNING LIGHTS AND BUZZERS
Check that all warning lights and buzzers function properly.
4. HORN
Check that it is working.
5. WINDSHIELD
Check for scratches, pits or abrasions.
6. WINDSHIELD WIPER AND WASHER
(a) Check operation of the wipers and washer.
(b) Check that the wipers do not streak.
7. WINDSHIELD DEFROSTER
Check that air comes out from the defroster outlet when operating the heater \
or air conditioner at defroster
mode.
8. REAR VIEW MIRROR
Check that it is mounted securely.
9. SUN VISORS
Check that they move freely and mounted securely.
10. STEELING WHEEL
Check that it has the specified freeplay. Be alert for changes in steering condition, such as hard steering,
excessive freeplay or strange noises.
11. SEATS
(a) Check that all front seat controls such as seat adjusters, seatback recl\
iner, etc. operate smoothly.
(b) Check that all latches lock securely in any position.
(c) Check that the head restraints move up and down smoothly and that the lo\
cks hold securely in any latch position.
(d) For folding −down rear seat backs, check that the latches look securely.
12. SEAT BELTS
(a) Check that the seat belt system such as buckles, retractors and anchors operat\
e properly and smooth-
ly.
(b) Check that the belt webbing is not cut, frayed, worn or damaged.
Brought to you by BirfMark
Brought to you by BirfMark
Version 1.11 - 03/16/2010

PP305−02
PP−8
−
PREPARATION EMISSION CONTROL
57
Author: Date:
1996 LAND CRUISER (RM451U)
EMISSION CONTROL
RECOMMENDED TOOLS
09082−00040TOYOTA Electrical Tester.
Brought to you by BirfMark
Brought to you by BirfMark
Version 1.11 - 03/16/2010

PP306−01
−
PREPARATION EMISSION CONTROL
PP−9
1996 LAND CRUISER (RM451U)
EQUIPMENT
HeaterTVV
OBD II scan toolEngine speed
ThermometerTVV
Torque wrench
Vacuum gauge
Brought to you by BirfMark
Brought to you by BirfMark
Version 1.11 - 03/16/2010

PP307−01
PP−10
−
PREPARATION EMISSION CONTROL
1996 LAND CRUISER (RM451U)
SSM (Special Service Materials)
08833−00070Adhesive 1324,
THREE BOND 1324 or equivalentTVV
Brought to you by BirfMark
Brought to you by BirfMark
Version 1.11 - 03/16/2010

PP−44
−
PREPARATION SUSPENSION AND AXLE
93
Author: Date:
1996 LAND CRUISER (RM451U)
09611−22012Tie Rod End PullerFront axle
09612−65014Steering Worm Bearing PullerFront axle
(09612−01010)Claw ”A”
(09612−01050)Hanger Pin with Nut
09618−60010Front Axle & Drive Shaft Bearing
ReplacerFront axle
09710−22021Front Suspension Bushing Tool
SetRear suspension
(09710−01071)Lower Arm Bushing Remover
09710−22042Rear Suspension Bushing Tool SetFront suspension
(09710−02051)Base
(09710−02061)Replacer
(09710−02071)Bushing Remover & Replacer
09710−30050Suspension Arm Bushing ReplacerFront suspension
09726−40010Lower Control Shaft Bearing
ReplacerFront differential
Rear differential
Brought to you by BirfMark
Brought to you by BirfMark
Version 1.11 - 03/16/2010

RS0P0−01
AB0250Spiral Cable
R13451
RS−2
−
SUPPLEMENTAL RESTRAINT SYSTEM SRS AIRBAG
1996 LAND CRUISER (RM451U)
OPERATION
1. STEERING WHEEL PAD (with AIRBAG)
The inflater and bag of the SRS are stored in the steering wheel
pad and cannot be disassembled. The inflater contains a squib,
igniter charge, gas generant, etc., and inflates the bag when
instructed by the airbag sensor assembly.
2. SPIRAL CABLE (in COMBINATION SWITCH)
A spiral cable is used as an electrical joint from the vehicle body
side to the steering wheel.
3. FRONT PASSENGER AIRBAG ASSEMBLY
The inflater and bag of the SRS are stored in the front passen-
ger airbag assembly and cannot be disassembled.The inflater
contains a squib, igniter charge, gas generant, etc., and inflates
the bag when instructed by the airbag sensor assembly.
4. SRS WARNING LIGHT
The SRS warning light is located on the combination meter. It
goes on to alert the driver of trouble in the system when a mal-
function is detected in the airbag sensor assembly. In normal
operating condition when the ignition switch is turned to the
ACC or ON position, the light goes on for about 6 seconds and
then goes off.
5. AIRBAG SENSOR ASSEMBLY
The airbag sensor assembly is mounted on the floor inside the
console box. The airbag sensor assembly consists of an airbag
sensor, safing sensor, diagnosis circuit and ignition control,
drive circuit, etc.
It receives signals from the airbag sensors and judges whether
the SRS must be activated or not.
Brought to you by BirfMark
Brought to you by BirfMark
Version 1.11 - 03/16/2010

SA−2
−
SUSPENSION AND AXLE TROUBLESHOOTING
859
Author: Date:
1996 LAND CRUISER (RM451U)
Oil leak from rear dif
ferential
1. Oil level: too high or wrong grade
2. Oil seal: worn or damaged
3. Companion flange: loosen or damagedSA−73
SA−73
SA−87
Indicator lights do not light up
1. Fusible link: blown
2. GAUGE fuse: blown
3. Bulb: burned out
4. Wiring or ground: faultyBE−9
BE−9
BE−32 −
Indicator lights do not light up
(Diff. lock control switch RR or FR RR position)
1. DIFF fuse: blown
2. Diff. lock control switch: faulty
3. Diff. lock ECU: faulty
4. Wiring or ground: faultyBE−9
SA−101
SA−101 −
Differential lock does not operate
1. Diff. lock position switch: faulty
2. Diff. lock actuator: faulty
3. Diff. lock ECU: faulty
4. Differential carrier (Diff. lock): faulty
5. Wiring or ground: faultySA−101
SA−101
SA−101
SA−101−
After differential lock, lock not release
When vehicle speed is higher than approx. 8 km/h (5mph)1. Speed sensor: faulty
2. Diff. lock ECU: faulty
3. Wiring or ground: faultyBE−32
SA−101 −
Brought to you by BirfMark
Brought to you by BirfMark
Version 1.11 - 03/16/2010

SA1UM−03
FA2038
−
SUSPENSION AND AXLE FRONT DIFFERENTIAL CARRIER
SA−27
1996 LAND CRUISER (RM451U)
REMOVAL
1. w/ DIFFERENTIAL LOCK:
BEFORE REMOVAL, SHIFT FRONT DIFFERENTIAL
TO LOCK
(a) Turn the ignition switch to the ON position.
(b) Keep the center differential lock condition.
(c) Turn the differential lock control switch to the FR/RR posi-
tion and lock the front differential.
(d) Rotating the tires, check they are in the differential lock condition.
(e) Disconnect the cable from the negative terminal of the battery.
2. DRAIN DIFFERENTIAL OIL
3. REMOVE FRONT AXLE SHAFTS (See page SA−13)
4. REMOVE TIE ROD FROM KNUCKLE ARM (See page SA−13 )
5. REMOVE FRONT PROPELLER SHAFT (See page PR−3 )
6. w/ DIFFERENTIAL LOCK: DISCONNECT CONNECTORS AND TUBE
HINT:
When connecting the tube of the harness side to the hose
of the actuator side, its depth of insertion is 15 mm (0.59
in.).
Take care that water or equivalent does not adhere to the
connector and hose.
Brought to you by BirfMark
Brought to you by BirfMark
Version 1.11 - 03/16/2010