Battery TOYOTA LAND CRUISER 1996 J80 Repair Manual

CH0HN−01
−
CHARGING CHARGING SYSTEM
CH−1
766
Author: Date:
1996 LAND CRUISER (RM451U)
PRECAUTION
CAUTION:
Check that the battery cables are connected to the correct terminals.
Disconnect the battery cables when the battery is given a quick charge.
Do not perform tests with a high voltage insulation resistance tester.
Never disconnect the battery while the engine is running.
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CH0EO−02
CH0712
BlueRed
White
Charging
Necessary
OK
Add Distilled
Water
CH−2
−
CHARGING CHARGING SYSTEM
1996 LAND CRUISER (RM451U)
CHARGING SYSTEM
ON−VEHICLE INSPECTION
1. CHECK BATTERY ELECTROLYTE LEVEL AND VOLT-
AGE
(a) Check the electrolyte quantity of each cell.
If under the lower level, replace the battery (or add distilled wa-
ter if possible). check the charging system.
(b) Measure the battery voltage between the negative ( −)
and positive (+) terminals of the battery.
Standard voltage: At 20° C (68°F): 12.7 − 12.9 V
HINT:
Before measuring the voltage, turn the ignition switch
OFF and turn off the electrical systems (headlight, blower
motor, rear defogger etc.).
If the vehicle has been running, wait 20 minutes or more
after the vehicle stops before measuring the battery volt-
age.
If the voltage is less than specification, charge the battery.
HINT:
Check the indicator as shown in the illustration.
2. CHECK BATTERY TERMINALS, FUSIBLE LINK AND FUSES
(a) Check that the battery terminals are not loose or cor-
roded.
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CH−4
−
CHARGING CHARGING SYSTEM
1996 LAND CRUISER (RM451U)
If the light does not operate as specified, troubleshoot the dis-
charge warning light circuit.
6. INSPECT CHARGING CIRCUIT WITHOUT LOAD
HINT:
If a battery/generator tester is available, connect the tester to
the charging circuit as per the manufacturer’s instructions.
(a) If a tester is not available, connect a voltmeter and amme-
ter to the charging circuit as follows:
Disconnect the wire from terminal B of the generator
and connect it to the negative ( −) lead of the amme-
ter.
Connect the positive (+) lead of the ammeter to ter-
minal B of the generator.
Connect the positive (+) lead of the voltmeter to ter-
minal B of the generator.
Ground the negative ( −) lead of the voltmeter.
(b) Check the charging circuit as follows:
With the engine running from idle to 2,000 rpm, check the
reading on the ammeter and voltmeter.
Standard amperage 10 A or less
Standard voltage:
at 25° C ’(77°F)14.0 − 15.0 V
at 115°C ’(239° F)13.5 − 14.3 V
If the voltmeter reading is more than standard voltage, replace
the voltage regulator.
If the voltmeter reading is less than the standard voltage, check
the voltage regulator and generator as follows:
With terminal F grounded, start the engine and
check the voltmeter reading of terminal B.
If the voltmeter reading is more than standard volt-
age, replace the voltage regulator.
If the voltmeter reading is less than standard volt-
age, check the generator.
7. INSPECT CHARGING CIRCUIT WITH LOAD
(a) With the engine running at 2,000 rpm, turn on the high
beam headlights and place the heater blower switch at
”HI”.
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−
CHARGING CHARGING SYSTEM
CH−5
1996 LAND CRUISER (RM451U)
(b) Check the reading on the ammeter.
Standard amperage: 30 A or more
If the ammeter reading is less than standard amperage, repair
the generator.
HINT:
If the battery is fully charged, the indication will sometimes be
less than standard amperage.
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CH0EP−01
CH−8
−
CHARGING GENERATOR
1996 LAND CRUISER (RM451U)
REMOVAL
1. REMOVE BATTERY AND BATTERY TRAY
2. DISCONNECT POWER STEERING (PS) RESERVOIR TANK
3. REMOVE DRIVE BELTS
(a) Loosen the lock bolt, pivot bolt and adjusting bolt.
(b) Remove the 2 drive belts.
4. REMOVE GENERATOR
(a) Disconnect the generator connector.
(b) Remove the rubber cap and nut, and disconnect the gen-
erator wire.
(c) Disconnect the generator wire clamp from the generator.
(d) Remove the lock bolt, bolt, nut and drive belt adjusting bar.
(e) Remove the pivot bolt and generator.
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CH06N−03
−
CHARGING GENERATOR
CH−19
1996 LAND CRUISER (RM451U)
INSTALLATION
1. INSTALL GENERATOR
(a) Mount generator on the generator bracket with the pivot
bolt. Do not tighten the bolt yet.
(b) Install the drive belt adjusting bar with the bolt and nut. Torque: 21 N·m (210 kgf·cm, 15 ft·lbf)
(c) Temporarily install the lock bolt.
(d) Connect the generator connector.
(e) Connect the generator wire with the nut and rubber cap.
(f) Connect the generator wire clamp to the generator.
2. INSTALL DRIVE BELTS
(a) Install the drive belts.
(b) Adjust the drive belt with the adjusting bolt (See page
CH−2 ).
(c) Tighten the pivot and adjusting lock bolts. Torque:
Pivot bolt: 59 N·m (600 kgf·cm, 43 ft·lbf)
Lock bolt: 21 N·m (210 kgf·cm, 15 ft·lbf)
3. CONNECT POWER STEERING (PS) RESERVOIR TANK
4. INSTALL BATTERY TRAY AND BATTERY
5. PERFORM ON−VEHICLE INSPECTION (See page CH−2 )
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CO117−02
CO−14
−
COOLING RADIATOR
1996 LAND CRUISER (RM451U)
REMOVAL
1. DRAIN ENGINE COOLANT
2. REMOVE BATTERY AND BATTERY TRAY
(a) Disconnect the battery cables.
(b) Remove the nuts, hold −down clamp and battery.
(c) Remove the bolt and disconnect the ground strap.
(d) Remove the 5 bolts and battery tray.
3. REMOVE RADIATOR GRILLE
Remove the 5 screws, clip and radiator grille.
4. DISCONNECT NO.3 WATER BYPASS HOSE
5. DISCONNECT RADIATOR INLET HOSE
6. DISCONNECT RADIATOR RESERVOIR HOSE
7. REMOVE RADIATOR
(a) Stretch the belts and loosen the water pump pulley mounting nuts.
(b) Loosen the lock, pivot and adjusting bolts of the genera- tor, and remove the drive belts.
(c) Disconnect the oil cooler hose from the clamp on the fan shroud.
(d) Remove the 2 bolts holding the fan shroud to the radiator.
(e) Remove the 4 water pump pulley mounting nuts.
(f) Pull out the fan with fluid coupling, water pump pulley and
fan shroud.
8. DISCONNECT A/T OIL COOLER HOSES
9. DISCONNECT RADIATOR OUTLET HOSE
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CO118−01
CO−16
−
COOLING RADIATOR
1996 LAND CRUISER (RM451U)
INSTALLATION
1. INSTALL RADIATOR
(a) Install the 2 radiator brackets with the 4 nuts. Torque: 12 N·m (120 kgf·cm, 9 ft·lbf)
(b) Install the radiator with the 2 bolts and 2 nuts. Torque:
Bolt: 18 N·m (185 kgf·cm, 13 ft·lbf)
Nut: 12 N·m (120 kgf·cm, 9 ft·lbf)
2. CONNECT A/T OIL COOLER HOSES
3. CONNECT RADIATOR OUTLET HOSE
4. INSTALL WATER PUMP PULLEY, FAN SHROUD, FAN WITH FLUID COUPLING AND DRIVE BELTS
(a) Place the fan with fluid coupling, water pump pulley and fan shroud in position.
(b) Temporarily install the fan pulley mounting nuts.
(c) Install the fan shroud with the 2 bolts. Torque: 5.0 N·m (50 kgf·cm, 43 in.·lbf)
(d) Connect the oil cooler hose to the clamp on the fan
shroud.
(e) Install the drive belts with the adjusting bolt and pivot bolt.
(f) Stretch the belts tight and tighten the 4 water pump pulley mounting nuts.
(g) Adjust the drive belts (See page CH−2 ).
5. CONNECT RADIATOR RESERVOIR HOSE
6. CONNECT RADIATOR INLET HOSE
7. CONNECT NO.3 WATER BYPASS HOSE
8. INSTALL RADIATOR GRILLE
Install the radiator grille with the 5 screws and clip.
9. INSTALL BATTERY AND BATTERY TRAY
(a) Install the battery tray with the 5 bolts.
(b) Connect the ground strap with the bolt.
(c) Install the battery with the hold−down clamp and nuts.
(d) Connect the battery cables.
10. FILL RADIATOR WITH ENGINE COOLANT
11. START ENGINE AND CHECK FOR LEAKS
12. CHECK AUTOMATIC TRANSMISSION FLUID LEVEL
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P22215
−
DIAGNOSTICS ENGINE
DI−5
1996 LAND CRUISER (RM451U)
Terminal No.
Connection / Voltage or ResistanceCondition
2Bus 
Line / Pulse generationDuring transmission
4Chassis Ground / ↔ Body Ground 1 Ω or lessAlways
5Signal Ground / ↔ Body Ground 1 Ω or lessAlways
16Battery Positive / ↔ Body Ground 9 − 14 VAlways
HINT:
If your display shows ”UNABLE TO CONNECT TO VEHICLE”
when you have connected the cable of the OBD II scan tool or
TOYOTA hand−held tester to DLC3, turned the ignition switch
ON and operated the scan tool, there is a problem on the ve-
hicle side or tool side.
If communication is normal when the tool is connected to
another vehicle, inspect DLC3 on the original vehicle.
If communication is still not possible when the tool is con-
nected to another vehicle, the problem is probably in the
tool itself, so consult the Service Department listed in the
tool’s instruction manual.
2. INSPECT DIAGNOSIS (NORMAL MODE)
(a) Check the MIL. (1) The MIL comes on when the ignition switch is turnedON and the engine is not running.
HINT:
If the MIL does not light up, troubleshoot the combination meter
(See page BE−2 ).
(2) When the engine started, the MIL should go off. If the lamp remains on, the diagnosis system has de-
tected a malfunction or abnormality in the system
(b) Check the DTC.
NOTICE:
TOYOTA hand−held tester only: When the diagnosis sys-
tem is switched from normal mode to check mode, it
erases all DTCs and freezed frame data recorded in normal
mode. So before switching modes, always check the DTCs
and freezed frame data, and note them down (1) Prepare the OBD II scan tool (complying with SAE
J 1978) or TOYOTA hand−held tester.
(2) Connect the OBD II scan tool or TOYOTA hand− held tester to DLC3 in the fuse box at the lower left
of the instrument panel.
(3) Turn the ignition switch ON and switch the OBD II
scan tool or TOYOTA hand −held tester switch ON.
(4) Use the OBD II scan tool or TOYOTA hand−held tester to check the DTC and freezed frame data,
note them down. (For operating instructions, see
the OBD II scan tool’s instruction book.)
(5) See page DI−13 to confirm the details of the
DTCs.
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FI3605
ON
OFF Flashing
0.13 Second
DI−6
−
DIAGNOSTICS ENGINE
1996 LAND CRUISER (RM451U)
NOTICE:
When simulating symptoms with an OBD II scan tool (ex-
cluding TOYOTA hand −held tester) to check the DTC, use
normal mode. For codes on the DTC chart subject to ”2 trip
detection logic”, turn the ignition switch OFF after the
symptom is simulated the first time. Then repeat the simu-
lation process again. When the problem has been simu-
lated twice, the MIL lights up and the DTCs are recorded in
the ECM.
3. INSPECT DIAGNOSIS (CHECK MODE)
HINT:
TOYOTA hand−held tester only:
Compared to the normal mode, the check mode has an in-
creased sensitivity to detect malfunctions.
Furthermore, the same diagnostic items which are detected in
the normal mode can also be detected in the check mode.
(a) Check the DTC. (1) Initial conditions
Battery positive voltage 11 V or more.
Throttle valve fully closed.
Transmission in ”park” or ”neutral” position.
Air conditioning switched OFF.
(2) Turn ignition switch OFF.
(3) Prepare the TOYOTA hand−held tester.
(4) Connect the TOYOTA hand−held tester to DLC3 in
the fuse box at the lower left of the instrument panel.
(5) Turn the ignition switch ON and push the TOYOTA hand−held tester ON.
(6) Switch the TOYOTA hand −held tester normal mode
to check mode (Check that the MIL flashes.).
(7) Switch the engine (The MIL goes out after the en- gine start.).
(8) Simulate the conditions of the malfunction de- scribed by the customer.
NOTICE:
Leave the ignition switch ON until you have checked the
DTC, etc. (9) After simulating the malfunction conditions, use theTOYOTA hand−held tester diagnosis selector to
check the DTCs and freezed 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.
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