be- TOYOTA LAND CRUISER 1996 J80 Owner's Manual

EM3322
EM−46
−
ENGINE MECHANICAL CYLINDER HEAD
1996 LAND CRUISER (RM451U)
(e) Inspect the gear spring
Using vernier calipers, measure the free distance be-
tween the spring ends.
Free distance: 18.2 − 18.8 mm (0.717 − 0.740 in.)
If the free distance is not as specified, replace the gear spring.
(f) Inspect the journal oil clearance. (1) Clean the bearing caps and camshaft journals.
(2) Place the camshafts on the cylinder head.
(3) Lay a strip of Plastigage across each of the cam-
shaft journals.
(4) Install the bearing caps (See page EM−54).
NOTICE:
Do not turn the camshaft. (5) Remove the bearing caps.
(6) Measure the Plastigage at its widest point.
Standard oil clearance:
0.025 − 0.062 mm (0.0010 − 0.0024 in.)
Maximum oil clearance: 0.10 mm (0.0039 in.)
If the oil clearance is greater than maximum, replace the cam-
shaft. If necessary, replace the bearing caps and cylinder head
as a set. (7) Completely remove the Plastigage.
(g) Inspect the thrust clearance. (1) Install the camshaft (See page EM−54 ).
(2) Using a dial indicator, measure the thrust clearance
while moving the camshaft back and forth.
Standard thrust clearance:
0.030 − 0.080 mm (0.0012 − 0.0031 in.)
Maximum thrust clearance: 0.10 mm (0.0039 in.)
If the thrust clearance is greater than maximum, replace the
camshaft. If necessary, replace the bearing caps and cylinder
head as a set.
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P22567A16077
2 Dot Marks
EM−56
−
ENGINE MECHANICAL CYLINDER HEAD
1996 LAND CRUISER (RM451U)
(a) Install the intake camshaft.
(1) Apply engine oil to the thrust portion of the intakecamshaft.
(2) Lightly place the intake camshaft on top of the cylin-
der head as shown in the illustration so that the No.
1 and No. 4 cylinder cam lobes face downward.
(3) Lightly push the camshaft towards the front without
applying excessive force.
(4) Place the No. 2 and No. 5 bearing caps in their prop-
er location.
(5) Temporarily tighten these bearing cap bolts uni- formly and alternately in several passes until the
bearing caps are snug with the cylinder head.
(6) Place the No. 3, No. 4, No. 6 and No. 7 bearing caps
in their proper location.
(7) Temporarily tighten these bearing cap bolts, alter- nately tightening the left and right bolts uniformly.
(8) Place the No. 1 bearing cap in its proper location. When doing this, check that there is no gap be-
tween the cylinder head and the contact surface of
bearing cap.
(9) Temporarily tighten the bearing cap bolts, alternate-
ly tightening the left and right bolts uniformly.
(10) Uniformly tighten the 14 bearing cap bolts in several
passes.
Torque: 16 N·m (160 kgf·cm, 12 ft·lbf)
(b) Install the exhaust camshaft. (1) Set the timing mark (2 dot marks) of the camshaftdrive gear at approx. 35 ° angle by turning the hexa-
gon wrench head portion of the intake camshaft
with a wrench.
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−
ENGINE MECHANICAL CYLINDER HEAD
EM−57
1996 LAND CRUISER (RM451U)
(2) Apply engine oil to thrust portion of the exhaust
camshaft.
(3) Engage the exhaust camshaft gear to the intake
camshaft gear by matching the timing marks (two
dot marks) on each gear.
(4) Roll down the exhaust camshaft onto the bearing journals while engaging gears with each other.
(5) Lightly push the intake camshaft towards the front without applying excessive force.
(6) Install the No. 4 and No. 6 bearing caps in their proper location.
(7) Temporarily tighten the bearing cap bolts uniformly and alternately in several passes until the bearing
caps are snug with the cylinder head.
(8) Place the No. 2, No. 3, No. 5 and No. 7 bearing caps
in their proper location.
(9) Temporarily tighten these bearing cap bolts, alter- nately tightening the left and right bolts uniformly.
(10) Place the No. 1 bearing cap in its proper location. When doing this, check that there is no gap be-
tween the cylinder head and the contact surface of
bearing cap.
(11) Temporarily tighten the bearing cap bolts, alternate-
ly tightening the left and right bolts uniformly.
(12) Uniformly tighten the 14 bearing cap bolts in several
passes.
Torque: 16 N·m (160 kgf·cm, 12 ft·lbf)
(13) Bring the service bolt installed in the driven sub −
gear upward by turning the hexagon wrench head
portion of the camshaft with a wrench.
(14) Remove the service bolt.
(15) Check that the intake and exhaust camshafts turn smoothly.
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P22576
−
LUBRICATION OIL PUMP
LU−7
1996 LAND CRUISER (RM451U)
(b) Remove the No.1 oil pan by prying the portions (A) be-
tween the cylinder block and No.1 oil pan with a screw-
driver.
NOTICE:
Be careful not to damage the contact surfaces of the cylin-
der block and No.1 oil pan.
14. REMOVE OIL PAN BAFFLE PLATE
Remove the bolt, 7 nuts and baffle plate.
15. REMOVE OIL STRAINER
Remove the bolt, 2 nuts, oil strainer and gasket.
16. REMOVE CRANKSHAFT PULLEY (See page EM−13 )
17. REMOVE DRIVE BELT IDLER PULLEY
Remove the bolt and idler pulley.
18. REMOVE OIL PUMP (TIMING CHAIN COVER) (See page EM−13 )
19. REMOVE TIMING CHAIN AND CAMSHAFT TIMING GEAR
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PP30G−03
−
PREPARATION LUBRICATION
PP−19
1996 LAND CRUISER (RM451U)
LUBRICANT
ItemCapacityClassification
Engine oil
Dry fill
Drain and refill w/ Oil filter change
w/o Oil filter change
8.0 liters (8.5 US qts, 7.0 Imp. qts)
7.4 liters (7.8 US qts, 6.5 Imp. qts)6.9 liters (7.3 US qts, 6.1 Imp qts)
API grade SH, Energy −Conserving II multigrade
engine oil or ILSAC multigrade engine oil and
recommended viscosity oil, with SAE 5W −30 be-
ing preferred engine oil
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RS0PC−03
−
SUPPLEMENTAL RESTRAINT SYSTEM FRONT PASSENGER AIRBAG ASSEMBLY
RS−31
1996 LAND CRUISER (RM451U)
INSTALLATION
NOTICE:
Never use airbag parts from another vehicle. When replac-
ing parts, replace with new parts.
1. INSTALL FRONT PASSENGER AIRBAG ASSEMBLY
Install the airbag door and front passenger airbag assembly to
the instrument panel.
CAUTION:
Make sure that no foreign objects are trapped be-
tween the airbag and the module.
Do not damage the strap when installing the module.
If the airbag door is cracked or its surface is peeling,
always replace it with a new airbag door.
NOTICE:
If the front passenger airbag assembly has been dropped,
or there are cracks, dents or other defects in the case or
connector, replace the front passenger airbag assembly
with a new one.
2. INSTALL INSTRUMENT PANEL (See page BO−80)
Install the 2 bolts to instrument panel reinforcement. Torque: 20 N·m (210 kgf·cm, 15 ft·lbf)
NOTICE:
Make sure the front passenger airbag assembly is installed
to the specified torque.When installing the instrument pan-
el, take care that the airbag wire harness does not interfere
with other parts and is not pinched between other parts.
3. CONNECT AIRBAG CONNECTOR
(a) Connect the airbag connector.
(b) Install the airbag connector to the airbag bracket.
(c) Install the glove compartment door.
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W00493
30 mm
(1.18 in.)
SA1UN−03
SA2465
SA2462
SA2403
−
SUSPENSION AND AXLE FRONT DIFFERENTIAL CARRIER
SA−29
1996 LAND CRUISER (RM451U)
DISASSEMBLY
1. CHECK RUNOUT OF COMPANION FLANGE
Using a dial indicator, measure the vertical and lateral runout of
the companion flange. Maximum runout: 0.10 mm (0.0039 in.)
2. CHECK RING GEAR RUNOUT
Using a dial indicator, measure the ring gear runout. Maximum runout: 0.10 mm (0.0039 in.)
If the runout is greater than the maximum, replace the ring gear
and driven pinion as a set.
3. CHECK RING GEAR BACKLASH
Using a dial indicator, measure the ring gear backlash. Backlash: 0.13 −0.18 mm (0.0051 −0.0071 in.)
If the backlash is not within the specification, adjust the side
bearing preload or repair as necessary.
4. MEASURE DRIVE PINION PRELOAD
Using a torque wrench, measure the preload of backlash be-
tween the drive pinion and ring gear. Preload (at starting):
0.5 − 0.8 N·m (5 − 8 kgf·cm, 4.3 − 6.9 in.·lbf)
5. CHECK TOTAL PRELOAD
Using a torque wrench, measure the preload. Total preload (at starting):
Drive pinion preload plus
0.4 − 0.6 N·m (4 − 6 kgf·cm, 3.5 − 5.2 in.·lbf)
If necessary, disassemble and inspect the differential.
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Z06898
SA2458
Matchmarks
SA2467SST
Z10281SST
SA2308
−
SUSPENSION AND AXLE FRONT DIFFERENTIAL CARRIER
SA−41
1996 LAND CRUISER (RM451U)
14. w/o DIFFERENTIAL LOCK:
INSTALL ADJUSTING NUTS
Install the adjusting nuts on the carrier , making sure the nuts are
threaded properly.
15. INSTALL BEARING CAPS
Align the matchmarks on the cap and carrier. Screw in the 2
bearing cap bolts 2 or 3 turns and press down the bearing cap
by hand.
HINT:
If the bearing cap does not fit tightly on the carrier , the adjusting
nuts are not threaded properly.
Reinstall the adjusting nuts if necessary.
16. ADJUST SIDE BEARING PRELOAD
(a) Torque the 4 bearing cap bolts to the specified torque, and loosen them to the point where the adjusting nuts can
be turned by SST.
SST 09504−00011
Torque: 78 N·m (800 kgf·cm, 58 ft·lbf)
(b) Fully tighten the 4 bearing cap bolts by hand.
(c) Using the SST, torque the adjusting nut on the ring gear side until the ring has a backlash of about 0.2 mm (0.008
in.).
(d) With turning the ring gear, use the SST to fully tighten the adjusting nut on the drive pinion side. After the bearings
are settled, loosen the adjusting nut on the drive pinion
side.
(e) Place a dial indicator on the top of the adjusting nut on the ring gear side.
(f) Adjust the side bearing for zero preload by tightening the
other adjusting nut until the pointer on the indicator be-
gins to move.
(g) Torque the adjusting nut 1 − 1.5 notches from the zero preload position.
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R08154
Matchmark
(Groove)
5
°
108 ° 1.5 V
32
SA2306
SA1992
R08218
−
SUSPENSION AND AXLE FRONT DIFFERENTIAL CARRIER
SA−47
1996 LAND CRUISER (RM451U)
(b) Ensure that the matchmarks of the pinion of the actuator
is in the extent between zero and 5 degrees clockwise
above the center line of the actuator.
If the matchmarks is not in this extent, rotate the pinion to be
matched. Do not supply the battery positive voltage directly be-
tween terminals. If the matchmarks come to the extension limit
of the rotation, do not electrify moreover.
(c) Install a new O−ring to the actuator.
(d) Apply a light coat of gear oil on the O −ring.
(e) Apply MP grease to the gear part.
(f) Insert the actuator so that the long hole on the actuator side fits with the knock pin on the carrier side.
HINT:
Do not damage the O −ring of the actuator.
(g) Align the actuator with the long hole and rotate the actua-
tor counterclockwise when the knock pin reaches the
right−hand side.
(h) Install the actuator to the differential carrier with the bolt so that the outermost rack tooth of the shift fork will fit the
matchmarks of the pinion of the actuator.
Torque: 26 N·m (270 kgf·cm, 20 ft·lbf)
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SA2450
SST
SA2446
R08261
R08262
−
SUSPENSION AND AXLE REAR DIFFERENTIAL CARRIER
SA−91
1996 LAND CRUISER (RM451U)
(d) Adjust the drive pinion preload by tightening the compan-
ion flange nut.
Using SST to hold the flange, tighten the nut.
SST 09330−00021
NOTICE:
Coat the nut and screw of the drive pinion with gear oil. As
there is no spacer, tighten a little at a time, being careful not
to overtighten.
(e) Using a torque wrench, measure the preload. Preload (at starting):
New bearing
1.3 − 2.0 N·m (13 − 20 kgf·cm, 11.3 − 17.4 in.·lbf)
Reused bearing
0.7 − 1.0 N·m (7 − 10 kgf·cm, 6.1 − 8.7 in.·lbf)
HINT:
Measure the total preload after first turning the bearing clock-
wise and counterclockwise several times to make the bearing
smooth.
10. w/o DIFFERENTIAL LOCK: INSTALL DIFFERENTIAL CASE IN CARRIER
(a) Place the 2 bearing outer races on their respective bear- ings. Make sure that the left and right outer races are not
interchanged.
(b) Install the case in the carrier.
HINT:
Make sure that there is backlash between the ring gear and
drive pinion.
11. w/ DIFFERENTIAL LOCK: INSTALL DIFFERENTIAL CASE IN CARRIER
(a) Place the 2 bearing outer races on their respective bear- ings. Make sure that the left and right races are not inter-
changed.
(b) Install the assembled plate washer onto the side bearing.
(c) Install the differential case in the carrier.
(d) Make the plate washer and bearing smooth by tapping on
the ring gear with a plastic hammer.
HINT:
If it is difficult to install the differential case into the carrier, re-
place the plate washer with a thinner one.
However, select a plate washer that allows no clearance be-
tween it and the carrier.
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