Indicator TOYOTA LAND CRUISER 1996 J80 Repair Manual

I00498
Cruise Control ECU
C17
Battery Fusible
Link
F6 B−L W
B
B G−Y
F11 F11
GAUGE
Y
2
Y9
CRUISE MAIN Indicator (Combination Meter)C10
C10
2 2 2
2
22
43
EA2
6
Ignition Switch
I12 I12
4
Instrument Panel Fuse Block
1
AM1
AM1 J1
JUNCTION
CONNECTOR
PI
7
DI−332
−
DIAGNOSTICS CRUISE CONTROL SYSTEM
1996 LAND CRUISER (RM451U)
CRUISE MAIN Indicator Light Circuit
CIRCUIT DESCRIPTION
When the cruise control main switch is turned ON, CRUISE MAIN indicator ligh\
t lights up.
WIRING DIAGRAM
DI5OP−02
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−
ENGINE MECHANICAL TIMING CHAIN
EM−15
1996 LAND CRUISER (RM451U)
15. CHECK THRUST CLEARANCE OF OIL PUMP DRIVE
SHAFT GEAR
Using a dial indicator with lever type attachment, measure the
thrust clearance.
Standard thrust clearance:
0.040 − 0.160 mm (0.0016 − 0.0063 in.)
Maximum thrust clearance: 0.30 mm (0.0118 in.)
If the thrust clearance is greater than maximum, replace the oil
pump drive shaft gear and/or timing chain cover.
16. REMOVE DRIVE BELT IDLER PULLEY
Remove the bolt and idler pulley.
17. REMOVE TIMING CHAIN COVER
(a) Remove the 9 mounting bolts, 2 mounting nuts and drive belt adjusting bar.
(b) Remove the oil pump by prying the portions between the cylinder block and oil pump with a screwdriver.
NOTICE:
Be careful not to damage the contact surfaces of the cylin-
der block and oil pump.
(c) Remove the O−rings from the oil pump.
(d) Remove the gasket from the oil pump.
18. REMOVE TIMING CHAIN AND CAMSHAFT TIMING GEAR
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EM0281
P03976
P03977
−
ENGINE MECHANICAL CYLINDER HEAD
EM−45
1996 LAND CRUISER (RM451U)
(c) Using a spring tester, measure the tension of the valve
spring at the specified installed length.
Installed tension:
214 − 238 N (21.8 − 24.2 kgf, 48.1 − 53.4 lbf)
at 36.5 mm (1.437 in.)
If the installed tension is not as specified, replace the valve
spring.
9. INSPECT CAMSHAFTS
(a) Inspect for runout. (1) Place the camshaft on V−blocks.
(2) Using a dial indicator, measure the circle runout atthe center journal.
Maximum circle runout: 0.06 mm (0.0024 in.)
If the circle runout is greater than maximum, replace the cam-
shaft.
(b) Inspect the cam lobes. Using a micrometer, measure the cam lobe height.
Standard cam lobe height:
50.61 − 50.71 mm (1.9925 − 1.9965 in.)
Minimum cam lobe height: 50.51 mm (1.9886 in.)
If the cam lobe height is less than minimum, replace the cam-
shaft.
(c) Inspect the journals. Using a micrometer, measure the journal diameter.
Journal diameter:
26.959 − 26.975 mm (1.0614 − 1.0620 in.)
If the journal diameter is not as specified, check the oil clear-
ance.
(d) Inspect the camshaft bearings. Check that bearings for flaking and scoring.
If the bearings are damaged, replace the bearing caps and cyl-
inder head as a set.
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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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EM2196
−
ENGINE MECHANICAL CYLINDER HEAD
EM−47
1996 LAND CRUISER (RM451U)
(h) Inspect the gear backlash.
(1) Install the camshafts without installing the exhaustcam sub−gear (See page EM−54).
(2) Using a dial indicator, measure the backlash.
Standard backlash:
0.020 − 0.200 mm (0.0008 − 0.0079 in.)
Maximum backlash: 0.30 mm (0.0188 in.)
If the backlash is greater than maximum, replace the cam-
shafts.
10. INSPECT VALVE LIFTER OIL CLEARANCE
(a) Using a caliper gauge, measure the lifter bore diameter of the cylinder head.
Lifter bore diameter:
34.000 − 34.021 mm (1.3386 − 1.3394 in.)
(b) Using a micrometer, measure the lifter diameter. Lifter diameter:
33.966 − 33.976 mm (1.3372 − 1.3376 in.)
(c) Subtract the lifter diameter measurement from the lifter bore diameter measurement.
Standard oil clearance:
0.024 − 0.055 mm (0.0009 − 0.0022 in.)
Maximum oil clearance: 0.07 mm (0.0028 in.)
If the oil clearance is greater than maximum, replace the lifter.
If necessary, replace the cylinder head.
11. INSPECT AIR INTAKE CHAMBER
Using a precision straight edge and thickness gauge, measure
the surface contacting the intake manifold for warpage. Maximum warpage: 0.30 mm (0.0118 in.)
If warpage is greater than maximum, replace the air intake
chamber.
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EM−84
−
ENGINE MECHANICAL CYLINDER BLOCK
1996 LAND CRUISER (RM451U)
9. REMOVE RH ENGINE MOUNTING BRACKET
(a) Remove the nut and insulator.
(b) Remove the 4 bolts and bracket.
10. REMOVE LH ENGINE MOUNTING BRACKET
(a) Remove the nut and insulator.
(b) Remove the 4 bolts and bracket.
11. REMOVE OIL COOLER COVER AND OIL COOLER
Remove the 10 bolts, 2 nuts, oil cooler cover with the oil cooler
and gasket.
12. REMOVE REAR OIL SEAL RETAINER
Remove the 4 bolts and retainer.
13. CHECK CONNECTING ROD THRUST CLEARANCE
Using a dial indicator, measure the thrust clearance while mov-
ing the connecting rod back and forth.
Standard thrust clearance:
0.160 − 0.262 mm (0.0063 − 0.0103 in.)
Maximum thrust clearance: 0.362 mm (0.0143 in.)
If the thrust clearance is greater than maximum, replace the
connecting rod assembly. If necessary , replace the crankshaft.
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P04620
−
ENGINE MECHANICAL CYLINDER BLOCK
EM−87
1996 LAND CRUISER (RM451U)
Standard sized bearing center wall thickness:
Mark ”2”1.744 − 1.747 mm (0.0687 − 0.0688 in.)
Mark ”3”1.747 − 1.750 mm (0.0688 − 0.0689 in.)
Mark ”4”1.750 − 1.753 mm (0.0689 − 0.0690 in.)
Mark ”5”1.753 − 1.756 mm (0.0690 − 0.0691 in.)
Mark ”6”1.756 − 1.759 mm (0.0691 − 0.0693 in.)
(k) Completely remove the Plastigage.
15. R E M O V E P I S TO N A N D C O N N E C T I N G R O D A S-
SEMBLIES
(a) Using a ridge reamer, remove the all carbon from the top of the cylinder.
(b) Push the piston, connecting rod assembly and upper bearing through the top of the cylinder block.
HINT:
Keep the bearings, connecting rod and cap together.
Arrange the piston and connecting rod assemblies in cor-
rect order.
16. CHECK CRANKSHAFT THRUST CLEARANCE
Using a dial indicator, measure the thrust clearance while prying
the crankshaft back and forth with a screwdriver. Standard thrust clearance:
0.020 − 0.220 mm (0.0008 − 0.0087 in.)
Maximum thrust clearance: 0.30 mm (0.0118 in.)
If the thrust clearance is greater than maximum, replace the
thrust washers as a set. Thrust washer thickness:
STD2.440 − 2.490 mm (0.0961 − 0.0980 in.)
O/S 0.1252.503 − 2.553 mm (0.0985 − 0.1005 in.)
O/S 0.2502.565 − 2.615 mm (0.1010 − 0.1030 in.)
17. REMOVE MAIN BEARING CAPS AND CHECK OIL
CLEARANCE
(a) Uniformly loosen and remove the main bearing cap bolts
in several passes, in the sequence shown.
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EM−98
−
ENGINE MECHANICAL CYLINDER BLOCK
1996 LAND CRUISER (RM451U)
HINT:
If the location of this area cannot be judged by visual inspection,
measure the outer diameter at the location shown in the illustra-
tion.
If the outside diameter is less than minimum, replace the con-
necting rod bolt and nut as a set.
6. INSPECT CRANKSHAFT
(a) Inspect for circle runout. (1) Place the crankshaft on V−blocks.
(2) Using a dial indicator, measure the circle runout atthe center journal.
Maximum circle runout: 0.06 mm (0.0024 in.)
If the circle runout is greater than maximum, replace the crank-
shaft.
(b) Inspect the main journals and crank pins. (1) Using a micrometer, measure the diameter of each
main journal and crank pin.
Main journal diameter:
STD68.982 − 69.000 mm (2.7158 − 2.7165 in.)
U/S 0.2568.745 − 68.755 mm (2.7065 − 2.7069 in.)
Crank pin diameter:
STD56.982 − 57.000 mm (2.2434 − 2.2441 in.)
U/S 0.2556.745 − 56.755 mm (2.2341 − 2.2344 in.)
If the diameter is not as specified, check the oil clearance (See
page EM−83 ). If necessary, grind or replace the crankshaft.
(2) Check each main journal and crank pin for taper and out−of−round as shown.
Maximum taper and out−of−round:
0.02 mm (0.0008 in.)
If the taper and out −of− round is greater than maximum, replace
the crankshaft.
7. IF NECESSARY, GRIND AND HONE MAIN JOURNALS
AND/OR CRANK PINS
Grind and hone the main journals and/or crank pins to the fin-
ished undersized diameter. Install new main journal and/or
crankshaft pin undersized bearings.
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PP302-01
PP-6
-
PREPARATION ENGINE MECHANICAL
1996 LAND CRUISER (RM451U)
EQUIPMENT
Caliper gauge
CO/HC meter
Compression gauge
Connecting rod aligner
Cylinder gauge
Dial indicator
Dye penetrant
Engine tune-up tester
Heater
Magnetic finger
Micrometer
OBD II scan toolEngine speed
Piston ring compressor
Piston ring expander
Plastigage
Precision straight edge
Soft brush
Spring testerValve spring
Steel squareValve spring
Thermometer
Torque wrench
Valve seat cutter
Vernier calipers
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PP30M−01
−
PREPARATION STARTING
PP−25
1996 LAND CRUISER (RM451U)
EQUIPMENT
Dial indicatorCommutator
Magnetic fingerSteel ball
PressMagnetic switch terminal kit
Pull scaleBrush spring
SandpaperCommutator
Torque wrench
V−blockCommutator
Vernier calipersCommutator, Brush
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