TOYOTA LAND CRUISER 1996 J80 Workshop Manual

EM1EE−02
EM−76
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ENGINE MECHANICAL ENGINE UNIT
1996 LAND CRUISER (RM451U)
INSTALLATION
1. CHECK TORQUE CONVERTER CLUTCH INSTALLA- TION
Using calipers and straight edge, measure from the installed
surface of the torque converter clutch to the front surface of the
transmission. Correct distance: 15.7 mm (0.618 in.) or more
If the distance is less than the specifications, check for an im-
proper installation.
2. INSTALL TRANSMISSION TO ENGINE
Install the transmission with the 7 bolts. Torque: 72 N·m (730 kgf·cm, 53 ft·lbf)
3. INSTALL T ORQUE CONVERTER CLUTCH MOUNTING
BOLTS
Install the 6 bolts by turning the crankshaft. Torque: 55 N·m (550 kgf·cm, 41 ft·lbf)
HINT:
First install the green colored bolt and then the remaining 5
bolts.
4. INSTALL HOLE PLUG
5. CONNECT THROTTLE CABLE TO THROTTLE BODY
6. INSTALL A/T OIL COOLER PIPES FOR TRANSMIS-
SION
(a) Temporarily install the 3 mounting bolts.
(b) Connect the 2 oil cooler pipes to the unions on the trans-
mission. Tighten the union nuts.
Torque: 34 N·m (350 kgf·cm, 25 ft·lbf)
(c) Tighten the 3 clamp mounting bolts.
7. INSTALL STARTER
(a) Install the starter with the 2 bolts. Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)
(b) Connect the starter connector.
8. CONNECT ENGINE WIRE TO TRANSMISSION
(a) Connect the 2 connectors from the transmission.
(b) Connect the PNP switch connector.
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ENGINE MECHANICAL ENGINE UNIT
EM−77
1996 LAND CRUISER (RM451U)
9. INSTALL OIL DIPSTICK GUIDE FOR TRANSMISSION
(a) Install a new O−ring to the dipstick guide.
(b) Apply a light coat of ATF to the O −ring.
(c) Connect the dipstick guide end to the tube of the oil pan, and install the dipstick guide with the 2 bolts.
(d) Install the dipstick.
(e) Connect the 2 breather hoses.
10. INSTALL ENGINE AND TRANSMISSION ASSEMBLY IN VEHICLE
(a) Attach the engine hoist chain to the engine hangers.
(b) Lower the engine and transmission assembly into the en-
gine compartment.
(c) Insert the stud bolts of the front engine mounting insula- tors into the stud bolt holes of the frame.
(d) Temporarily install the 2 nuts holding the engine front mounting insulators to the frame crossmember.
(e) Keep the engine level with a jack.
(f) Remove the hoist chain.
11. INSTALL FRAME CROSSMEMBER
(a) Temporarily install the crossmember to the engine rear mounting insulator with the 2 nuts.
(b) Install the 8 bolts holding the crossmember to the frame. Torque: 61 N·m (620 kgf·cm, 45 ft·lbf)
(c) Tighten the 2 nuts holding the crossmember to the engine
rear mounting insulator.
Torque: 74 N·m (750 kgf·cm, 54 ft·lbf)
12. TIGHTEN NUTS HOLDING ENGINE FRONT MOUNT- ING INSULATORS TO FRAME
Torque: 74 N·m (750 kgf·cm, 54 ft·lbf)
13. CONNECT GROUND STRAP TO HEAT INSULATOR
14. INSTALL FRONT EXHAUST PIPE
(a) Install 2 new gaskets and the front exhaust pipe with the
4 nuts.
Torque: 63 N·m (630 kgf·cm, 46 ft·lbf)
(b) Install the No.1 support bracket with the 2 bolts.
Torque: 24 N·m (240 kgf·cm, 17 ft·lbf)
(c) Connect the clamp and tighten the clamp bolt. Torque: 19.5 N·m (195 kgf·cm, 14 ft·lbf)
(d) Connect the front exhaust pipe to the rear TWC with a
new gasket, 2 bolts and 2 nuts.
Torque: 46 N·m (470 kgf·cm, 34 ft·lbf)
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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)
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ENGINE MECHANICAL ENGINE UNIT
EM−79
1996 LAND CRUISER (RM451U)
16. Differential Side:
INSTALL FRONT AND REAR PROPELLER SHAFTS
(a) Align the matchmarks on the flanges and connect the
flanges with the 4 bolts and nuts.
(b) Torque the bolts and nuts. Torque:
74 N·m (750 kgf·cm, 54 ft·lbf) for front shaft
88 N·m (900 kgf·cm, 65 ft·lbf)for rear shaft
17. Transfer Side: INSTALL FRONT AND REAR PROPELLER SHAFTS
(a) Align the matchmarks on the flanges and connect the flanges with the 4 nuts.
(b) Torque the nuts. Torque:
74 N·m (750 kgf·cm, 54 ft·lbf) for front shaft
88 N·m (900 kgf·cm, 65 ft·lbf) for rear shaft
18. INSTALL STABILIZER BAR
(a) Temporarily install the stabilizer bar to the axle housing with the bolt and nut.
(b) Connect the stabilizer bar with the 2 bolts. Torque: 18 N·m (185 kgf·cm, 13 ft·lbf)
(c) Bounce the vehicle up and down to stabilize the suspen- sion.
(d) Torque the bolt and nut holding the stabilizer bar to the axle housing.
Torque: 25 N·m (260 kgf·cm, 19 ft·lbf)
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EM−80
−
ENGINE MECHANICAL ENGINE UNIT
1996 LAND CRUISER (RM451U)
19. CONNECT ENGINE WIRE TO CABIN
(a) Push in the engine wire through the cowl panel.
(b) Connect the connectors.
(1) Connect the 3 connectors to the ECM.
(2) Connect the 2 connectors to the cowl wire.
(c) Connect the A/C amplifier with the screw.
(d) Install the speaker panel with the screw.
(e) Install the glove compartment door with the 2 screws.
20. CONNECT PS RETURN HOSE
Connect the return hose to the PS reservoir tank.
21. CONNECT PS PRESSURE HOSE
Connect the PS pressure hose with 2 new gaskets and the
union bolt. Torque: 56 N·m (575 kgf·cm, 42 ft·lbf)
22. INSTALL RADIATOR PIPE
(a) Connect the No. 2 radiator hose to the water inlet.
(b) Install the 2 nuts holding the radiator pipe to the No. 1 oil pan.
Torque: 21 N·m (210 kgf·cm, 15 ft·lbf)
23. INSTALL A/C COMPRESSOR AND BRACKET
(a) Install the A/C compressor bracket with the 5 bolts.
Torque: 37 N·m (375 kgf·cm, 27 ft·lbf)
(b) Install the A/C compressor with the 4 bolts. Torque: 25 N·m (250 kgf·cm, 18 ft·lbf)
(c) Install and adjust the drive belt (See page CH−2).
24. CONNECT WIRES AND CONNECTORS
(a) Connect the 2 heated oxygen sensor connectors.
(b) Connect the DLC1 clamp.
(c) Connect the 2 oil pressure gauge connectors.
(d) Connect the generator wire and connector.
(e) Connect the connector on the intake manifold to the fend-
er apron.
(f) Connect the high −tension cord to the ignition coil.
(g) Connect the ground strap to the No. 1 engine hanger.
(h) Connect the ground strap to the air intake chamber.
(i) Connect the starter wire.
(j) Connect the ground cable to the cylinder block.
25. CONNECT FUEL HOSES
(a) Connect the fuel inlet hose to the fuel filter with 2 new gas-
kets and the union bolt.
Torque: 29 N·m (300 kgf·cm, 22 ft·lbf)
(b) Connect the fuel return hose.
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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
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EM1EF−01
EM−82
−
ENGINE MECHANICAL CYLINDER BLOCK
585
Author: Date:
1996 LAND CRUISER (RM451U)
CYLINDER BLOCK
COMPONENTS
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EM1Q8−01
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ENGINE MECHANICAL CYLINDER BLOCK
EM−83
1996 LAND CRUISER (RM451U)
DISASSEMBLY
1. REMOVE DRIVE PLATE
Uniformly loosen and remove the drive plate bolts, in several
passes, in the sequence shown.
2. INSTALL ENGINE TO ENGINE STAND FOR DIS-
ASSEMBLY
3. REMOVE CYLINDER HEAD (See page EM−28 )
4. REMOVE TIMING CHAIN AND GEARS (See page EM−13 )
5. REMOVE OIL FILTER (See page LU−2)
6. REMOVE OIL FILTER UNION
7. REMOVE KNOCK SENSORS
Using SST, remove the 2 knock sensors. SST 09816−30010
8. REMOVE PS PUMP
(a) Remove the 2 nuts and pump.
(b) Remove the O−ring from the pump.
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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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ENGINE MECHANICAL CYLINDER BLOCK
EM−85
1996 LAND CRUISER (RM451U)
14. REMOVE CONNECTING ROD CAPS AND CHECK OIL
CLEARANCE
(a) Check the matchmarks on the connecting rod cap and
connecting rod to ensure correct reassembly.
(b) Remove the connecting rod cap nuts.
(c) Using a plastic− faced hammer, lightly tap the connecting
rod bolts and lift off the connecting rod cap.
HINT:
Keep the lower bearing inserted with the connecting rod cap.
(d) Cover the connecting rod bolts with a short piece of hose to protect the crankshaft from damage.
(e) Clean the crank pin and bearing.
(f) Check the crank pin and bearing for pitting and scratches.
If the crank pin or bearing is damaged, replace the bearings. If
necessary, grind or replace the crankshaft.
(g) Lay a strip of Plastigage across the crank pin.
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