engine TOYOTA LAND CRUISER 1996 J80 Workshop Manual

SF0Y1−06
SF−22
−
SFI FUEL PRESSURE REGULATOR
1996 LAND CRUISER (RM451U)
INSTALLATION
1. INSTALL FUEL PRESSURE REGULATOR
(a) Fully loosen the lock nut on the pressure regulator.
(b) Apply a light coat of gasoline to a new O −ring, and install
it to the pressure regulator.
(c) Insert the pressure regulator into the delivery pipe by hand completely.
(d) Turn the pressure regulator counterclockwise until the fuel outlet port faces in the direction indicated in the il-
lustration.
(e) Tighten the lock nut. Torque: 25 N·m (250 kgf·cm, 18 ft·lbf)
2. CONNECT FUEL RETURN HOSE TO FUEL PRES-
SURE REGULATOR
3. CONNECT V ACUUM SENSING HOSE TO FUEL PRES-
SURE REGULATOR
4. START ENGINE AND CHECK FOR FUEL LEAKAGE
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SF0Y1−06
SF−22
−
SFI FUEL PRESSURE REGULATOR
1996 LAND CRUISER (RM451U)
INSTALLATION
1. INSTALL FUEL PRESSURE REGULATOR
(a) Fully loosen the lock nut on the pressure regulator.
(b) Apply a light coat of gasoline to a new O −ring, and install
it to the pressure regulator.
(c) Insert the pressure regulator into the delivery pipe by hand completely.
(d) Turn the pressure regulator counterclockwise until the fuel outlet port faces in the direction indicated in the il-
lustration.
(e) Tighten the lock nut. Torque: 25 N·m (250 kgf·cm, 18 ft·lbf)
2. CONNECT FUEL RETURN HOSE TO FUEL PRES-
SURE REGULATOR
3. CONNECT V ACUUM SENSING HOSE TO FUEL PRES-
SURE REGULATOR
4. START ENGINE AND CHECK FOR FUEL LEAKAGE
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SF1EN−01
SF−26
−
SFI INJECTOR
1996 LAND CRUISER (RM451U)
REMOVAL
1. DRAIN ENGINE COOLANT
2. DISCONNECT CRUISE CONTROL ACTUATOR CABLE
3. DISCONNECT ACCELERATOR CABLE
4. DISCONNECT THROTTLE CABLE
5. DISCONNECT NO.2 PCV HOSE
6. DISCONNECT AIR CLEANER HOSE
7. REMOVE EGR VACUUM MODULATOR AND VALVE (See page EC−10 )
8. REMOVE BOLT HOLDING HEATER INLET PIPE AND AIR INTAKE CHAMBER
9. DISCONNECT NO.1 PCV HOSE
10. DISCONNECT VACUUM SENSING HOSE
11. DISCONNECT NO.2 WATER BYPASS HOSE
12. DISCONNECT EVAP HOSE
13. DISCONNECT BRAKE BOOSTER HOSE
14. DISCONNECT THROTTLE POSITION SENSOR CON- NECTOR
15. DISCONNECT IDLE AIR CONTROL VALVE CONNEC-
TOR
16. DISCONNECT CONNECTOR FOR EMISSION CON- TROL VALVE SET ASSEMBLY
17. DISCONNECT EGR GAS TEMP. SENSOR CONNEC-
TOR
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−
SFI INJECTOR
SF−27
1996 LAND CRUISER (RM451U)
18. DISCONNECT PS RESERVOIR TANK
Remove the 3 bolts and disconnect the reservoir tank.
19. REMOVE ENGINE OIL DIPSTICK
20. DISCONNECT GROUND STRAP
21. REMOVE INTAKE MANIFOLD STAY
Remove the 2 bolts and intake manifold stay.
22. DISCONNECT VACUUM HOSES FROM TVV
23. DISCONNECT NO.1 WATER BYPASS HOSE FROM
CYLINDER HEAD
24. REMOVE AIR INTAKE CHAMBER
Remove the 6 bolts, 2 nuts, air intake chamber and 2 gaskets.
25. REMOVE FUEL RETURN PIPE
(a) Disconnect the fuel hose from the fuel pressure regulator.
(b) Remove the 2 bolts and fuel return pipe.
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FI4848
FI4849
SF−30
−
SFI INJECTOR
1996 LAND CRUISER (RM451U)
(f) Install the grommet and O−ring to the injector.
(g) Connect SST (union and hose) to the injector, and hold
the injector and union with SST (clamp).
SST 09268−41046
(h) Put the injector into the graduated cylinder.
HINT:
Install a suitable vinyl hose onto the injector to prevent gasoline
from splashing out.
(i) Remove the fuse cover on the instrument panel.
(j) Connect the TOYOTA hand−held tester to the DLC3.
(k) Turn the ignition switch ON and TOYOTA hand−held tes-
ter main switch ON.
NOTICE:
Do not start the engine.
(l) Select the active test mode on the TOYOTA hand −held
tester.
(m) Please refer to the TOYOTA hand −held tester operator’s
manual for further details.
(n) If you have no TOYOTA hand−held tester, connect the positive (+) and negative (−) leads from the battery to the
fuel pump connector (See page SF−14)
(o) Connect SST (wire) to the injector and battery for 15 se- conds, and measure the injection volume with a gra-
duated cylinder. Test each injector 2 or 3 times.
SST 09842−30070
Volume:
69 − 88 cm
3 (4.2 − 5.4 cu in.) per 15 seconds
Difference between each injector:
5 cm
3 (0.3 cu in.) or less
If the injection volume is not as specified, replace the injector.
2. INSPECT LEAKAGE
(a) In the condition above, disconnect the test probes of SST (wire) from the battery and check the fuel leakage from
the injector.
SST 09842−30070
Fuel drop: One drop or less per minute
(b) Turn the ignition switch to LOCK.
(c) Disconnect the negative ( −) terminal cable from the bat-
tery.
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SF−34
−
SFI INJECTOR
1996 LAND CRUISER (RM451U)
7. INSTALL INTAKE MANIFOLD STAY
Install the intake manifold stay with the 2 bolts.
Torque: 36 N·m (360 kgf·cm, 26 ft·lbf)
8. CONNECT GROUND STRAP
9. INSTALL ENGINE OIL DIPSTICK
10. CONNECT PS RESERVOIR TANK
Connect the reservoir tank with the 3 bolts. Torque: 18 N·m (185 kgf·cm, 13 ft·lbf)
11. CONNECT EGR GAS TEMP. SENSOR CONNECTOR
12. CONNECT CONNECTOR FOR EMISSION CONTROL VALVE SET ASSEMBLY
13. CONNECT IDLE AIR CONTROL VALVE CONNECTOR
14. CONNECT THROTTLE POSITION SENSOR CONNEC- TOR
15. CONNECT BRAKE BOOSTER HOSE
16. CONNECT EVAP HOSE
17. CONNECT NO.2 WATER BYPASS HOSE
18. CONNECT VACUUM SENSING HOSE
19. CONNECT NO.1 PCV HOSE
20. INSTALL BOLT HOLDING HEATER INLET PIPE AND AIR INTAKE CHAMBER
Torque: 20 N·m (200 kgf·cm, 14 ft·lbf)
21. INSTALL EGR VALVE AND VACUUM MODULATOR (See page EC−10 )
22. CONNECT THROTTLE CABLE
23. CONNECT ACCELERATOR CABLE
24. CONNECT CRUISE CONTROL ACTUATOR CABLE
25. CONNECT AIR CLEANER HOSE
26. CONNECT NO.2 PCV HOSE
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−
SFI INJECTOR
SF−35
1996 LAND CRUISER (RM451U)
27. FILL WITH ENGINE COOLANT
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SF1EU−01
SF−42
−
SFI THROTTLE BODY
670
Author: Date:
1996 LAND CRUISER (RM451U)
THROTTLE BODY
ON−VEHICLE INSPECTION
1. INSPECT THROTTLE BODY
(a) Check that the throttle linkage moves smoothly.
(b) Check the vacuum at each port.
Start the engine.
Check the vacuum with your finger.
Port nameAt idleAt 3,500 rpm
PNo vacuumVacuum
ENo vacuumVacuum
RNo vacuumVacuum
2. INSPECT THROTTLE POSITION (TP) SENSOR
(a) Disconnect the TP sensor connector.
(b) Apply vacuum to the throttle opener.
(c) Using an ohmmeter, measure the resistance between
each terminal.
Throttle valve
conditionBetween terminalsResistance
Fully closedVTA − E20.2 − 5.7 kΩ
Fully closedIDL − E22.3 kΩ or less
OpenIDL − E2Infinity
Fully openVTA − E22.0 − 10.2 kΩ
−VC − E22.5 − 5.9 kΩ
(d) Reconnect the TP sensor connector.
3. INSPECT AND ADJUST DASHPOT
(a) Allow the engine to warm up to normal operating tempera-
ture.
(b) Check the idle speed.
Idle speed: 650 ± 50 rpm (N position)
(c) Open the throttle valve until the throttle lever separates from the dashpot end.
(d) Release the throttle valve gradually, and check the dash-
pot setting speed when the throttle lever touched the
dashpot end.
Dashpot setting speed: 2,200 ± 300 rpm
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−
SFI THROTTLE BODY
SF−43
671
Author: Date:
1996 LAND CRUISER (RM451U)
If not as specified, adjust using the following procedure:
(1) Stop the engine.
(2) Loosen the lock nut of the stopper bolt.
(3) Adjust the dashpot setting speed by turning thestopper bolt.
(4) Start the engine and check the dashpot setting speed.
(5) Retighten the lock nut.
(e) Maintain the engine at 3,500 rpm.
(f) Release the throttle valve, and check that the engine re- turns to idle in a few seconds.
4. CHECK THROTTLE OPENER
(a) Disconnect the vacuum hose from the throttle opener, and plug the hose end.
(b) Check the throttle opener setting speed. Throttle opener setting speed: 700 − 1,000 rpm
If the throttle opener setting is not as specified, replace the
throttle body.
(c) Stop the engine.
(d) Reconnect the vacuum hose to the throttle opener.
(e) Start the engine, and check that the idle speed returns to the correct speed.
Idle speed: 650 ± 50 rpm (N position)
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SF1EW−04
−
SFI THROTTLE BODY
SF−45
1996 LAND CRUISER (RM451U)
REMOVAL
1. DRAIN ENGINE COOLANT
2. DISCONNECT NO.2 PCV HOSE
3. DISCONNECT AIR CLEANER HOSE
4. DISCONNECT CONTROL CABLES FROM THROTTLE
BODY
5. DISCONNECT THROTTLE POSITION SENSOR CON-
NECTOR
6. DISCONNECT IDLE AIR CONTROL VALVE CONNEC- TOR
7. REMOVE THROTTLE BODY
(a) Disconnect the EVAP hose.
(b) Disconnect the 3 vacuum hoses.
(c) Disconnect the No.2 water bypass hose.
(d) Remove the 4 bolts, and disconnect the throttle body from
the air intake chamber.
Torque: 21 N·m (210 kgf·cm, 15 ft·lbf)
(e) Remove the throttle body gasket.
HINT:
At the time of installation, plaese refer to the following items.
install a new gasket on the air intake chamber.
(f) Disconnect the No.1 water bypass hose from the throttle
body, and remove the throttle body.
(g) Disconnect the No.2 water bypass hose from the throttle
body.
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