Over drive TOYOTA LAND CRUISER 1996 J80 Workshop Manual

Illustration:
what to do and where 21. CHECK
PISTON STROKE OF OVERDRIVE BRAKE
(a)
Task heading : what to do
SST 09350− 30020 (09350 −06120)
Set part No. Component part No.
Detailed text : how to do task
(b)
Piston stroke: 1.40  1.70 mm (0.0551  0.0669 in.)
Specification
Place SST and a dial indicator onto the overdrive brake pis-
ton as shown in the illustration.
Measure the stroke applying and releasing the compressed
air (392  785 kPa, 4  8 kgf/cm2 or 57 
114 psi) as shown
in the illustration.
IN−2
−
INTRODUCTION HOW TO USE THIS MANUAL
2
Author: Date:
1996 LAND CRUISER (RM451U)
The procedures are presented in a step −by−step format:
The illustration shows what to do and where to do it.
The task heading tells what to do.
The detailed text tells how to perform the task and gives other information\
such as specifications
and warnings.
Example:
This format provides the experienced technician with a FAST TRACK to the information needed. The upper
case task heading can be read at a glance when necessary, and the text below it provides detailed informa-
tion. Important specifications and warnings always stand out in bold type.
6. REFERENCES
References have been kept to a minimum. However, when they are required you are given the page to refer
to.
7. SPECIFICATIONS
Specifications are presented in bold type throughout the text where needed. You never have to leave the
procedure to look up your specifications. They are also found in Service Specificatio\
ns section for quick ref-
erence.
8. CAUTIONS, NOTICES, HINTS:
CAUTIONS are presented in bold type, and indicate there is a possibility of injury to you or other\
people.
NOTICES are also presented in bold type, and indicate the possibility of damage to the components
being repaired.
HINTS are separated from the text but do not appear in bold. They provide additional information to
help you perform the repair efficiently.
9. SI UNIT
The UNITS given in this manual are primarily expressed according to the SI UNIT (Intern\
ational System of
Unit), and alternately expressed in the metric system and in the English Syste\
m.
Example:
Torque: 30 N·m (310 kgf·cm, 22 ft·lbf)
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Illustration:
what to do and where 21. CHECK
PISTON STROKE OF OVERDRIVE BRAKE
(a)
Task heading : what to do
SST 09350− 30020 (09350 −06120)
Set part No. Component part No.
Detailed text : how to do task
(b)
Piston stroke: 1.40  1.70 mm (0.0551  0.0669 in.)
Specification
Place SST and a dial indicator onto the overdrive brake pis-
ton as shown in the illustration.
Measure the stroke applying and releasing the compressed
air (392  785 kPa, 4  8 kgf/cm2 or 57 
114 psi) as shown
in the illustration.
IN−2
−
INTRODUCTION HOW TO USE THIS MANUAL
2
Author: Date:
1996 LAND CRUISER (RM451U)
The procedures are presented in a step −by−step format:
The illustration shows what to do and where to do it.
The task heading tells what to do.
The detailed text tells how to perform the task and gives other information\
such as specifications
and warnings.
Example:
This format provides the experienced technician with a FAST TRACK to the information needed. The upper
case task heading can be read at a glance when necessary, and the text below it provides detailed informa-
tion. Important specifications and warnings always stand out in bold type.
6. REFERENCES
References have been kept to a minimum. However, when they are required you are given the page to refer
to.
7. SPECIFICATIONS
Specifications are presented in bold type throughout the text where needed. You never have to leave the
procedure to look up your specifications. They are also found in Service Specificatio\
ns section for quick ref-
erence.
8. CAUTIONS, NOTICES, HINTS:
CAUTIONS are presented in bold type, and indicate there is a possibility of injury to you or other\
people.
NOTICES are also presented in bold type, and indicate the possibility of damage to the components
being repaired.
HINTS are separated from the text but do not appear in bold. They provide additional information to
help you perform the repair efficiently.
9. SI UNIT
The UNITS given in this manual are primarily expressed according to the SI UNIT (Intern\
ational System of
Unit), and alternately expressed in the metric system and in the English Syste\
m.
Example:
Torque: 30 N·m (310 kgf·cm, 22 ft·lbf)
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−
INTRODUCTION FOR ALL OF VEHICLES
IN−15
15
Author: Date:
1996 LAND CRUISER (RM451U)
3. FOR VEHICLES EQUIPPED WITH A CATALYTIC CONVERTER
CAUTION:
If large amount of unburned gasoline flows into the converter, it may overheat and create a fire haz-
ard. To prevent this, observe the following precautions and explain them to yo\
ur customer.
(a) Use only unleaded gasoline.
(b) Avoid prolonged idling.
Avoid running the engine at idle speed for more than 20 minutes.
(c) Avoid spark jump test. (1) Perform spark jump test only when absolutely necessary. Perform this test as rapidly as possible.
(2) While testing, never race the engine.
(d) Avoid prolonged engine compression measurement. Engine compression tests must be done as rapidly as possible.
(e) Do not run engine when fuel tank is nearly empty. This may cause the engine to misfire and create an extra load on the con\
verter.
(f) Avoid coasting with ignition turned off.
(g) Do not dispose of used catalyst along with parts contaminated with gasol\
ine or oil.
4. IF VEHICLE IS EQUIPPED WITH MOBILE COMMUNICATION SYSTEM
For vehicles with mobile communication systems such as two− way radios and cellular telephones, observe
the following precautions. (1) Install the antenna as far as possible away from the ECU and sensors of the vehicle’\
s electronic
system.
(2) Install the antenna feeder at least 20 cm (7.87 in.) away from the ECU and se\
nsors of the ve- hicle’s electronic systems. For details about ECU and sensors locations, refer\
to the section on
the applicable component.
(3) Avoid winding the antenna feeder together with other wiring as much as possible, and also avoid
running the antenna feeder parallel with other wire harnesses.
(4) Check that the antenna and feeder are correctly adjusted.
(5) Do not install powerful mobile communications system.
5. FOR USING OBD II SCAN TOOL OR TOYOTA HAND −HELD TESTER
CAUTION:
Observe the following items for safety reasons:
Before using the OBD II scan tool or TOYOTA hand −held tester, the OBD II scan tool’s instruc-
tion book or TOYOTA hand −held tester’s operator manual should be read thoroughly.
Be sure to route all cables securely when driving with the OBD II scan too\
l or TOYOTA hand −
held tester connected to the vehicle. (i.e. Keep cables away from feet,\
pedals, steering wheel
and shift lever.)
Two persons are required when test driving with the OBD II scan tool or TOYOTA hand −held
tester, one person to drive the vehicle and the other person to operate the OBD\
II scan tool or
TOYOTA hand−held tester.
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IN−34
−
INTRODUCTION TERMS
34
Author: Date:
1996 LAND CRUISER (RM451U)
CW
Curb W
eight
DCDirect Current
DEFDefogger
DFLDeflector
DIFF.Differential
DIFF. LOCKDifferential Lock
D/INJDirect Injection
DLIDistributorless Ignition
DOHCDouble Over Head Cam
DPDash Pot
DSDead Soak
DSPDigital Signal Processor
EBDElectronic Brake Force Distribution
ECAMEngine Control And Measurement System
ECDElectronic Controlled Diesel
ECDYEddy Current Dynamometer
ECUElectronic Control Unit
EDElectro−Deposited Coating
EDICElectric Diesel Injection Control
EDUElectronic Driving Unit
EFIElectronic Fuel Injection
E/GEngine
EGR−VMExhaust Gas Recirculation −Vacuum Modulator
ELREmergency Locking Retractor
ENGEngine
ESAElectronic Spark Advance
ETCSElectronic Throttle Control System
EVPEvaporator
E−VRVElectric V acuum Regulating V alve
EXHExhaust
FEFuel Economy
FFFront−Engine Front− Wheel−Drive
F/GFuel Gage
FIPGFormed In Place Gasket
FLFusible Link
F/PFuel Pump
FPUFuel Pressure Up
FrFront
FRFront−Engine Rear− Wheel−Drive
F/WFlywheel
FW/DFlywheel Damper
FWDFront−Wheel−Drive
GASGasoline
GSAGear Shift Actuator
GNDGround
HACHigh Altitude Compensator
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IN−36
−
INTRODUCTION TERMS
36
Author: Date:
1996 LAND CRUISER (RM451U)
NA
Natural Aspiration
No.Number
O/DOverdrive
OEMOriginal Equipment Manufacturing
OHCOverhead Camshaft
OHVOverhead V
alve
OPTOption
O/SOversize
P & BVProportioning And Bypass Valve
PCSPower Control System
PCVPositive Crankcase Ventilation
PKBParking Brake
PPSProgressive Power Steering
PSPower Steering
PTOPower Take−Off
R & PRack And Pinion
R/BRelay Block
RBSRecirculating Ball Type Steering
R/FReinforcement
RFSRigid Front Suspension
RHRight−Hand
RHDRight−Hand Drive
RLYRelay
ROMRead Only Memory
RrRear
RRRear−Engine Rear −Wheel Drive
RRSRigid Rear Suspension
RWDRear− Wheel Drive
SDNSedan
SENSensor
SICSStarting Injection Control System
SMTSequential Manual T ransmission
SOCState Of Charge
SOHCSingle Overhead Camshaft
SPECSpecification
SPISingle Point Injection
SRSSupplemental Restraint System
SSMSpecial Service Materials
SSTSpecial Service Tools
STDStandard
STJCold−Start Fuel Injection
SWSwitch
SYSSystem
T/ATransaxle
TACHTachometer
TBIThrottle Body Electronic Fuel Injection
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AC2R7−04
AC0943
SST
AC0944
SST
AC0945
SST
−
AIR CONDITIONING COMPRESSOR AND MAGNETIC CLUTCH
AC−35
1996 LAND CRUISER (RM451U)
DISASSEMBLY
1. RUN ENGINE AT IDLE SPEED WITH A/C SWITCH ON
FOR 10 MINUTES
2. STOP ENGINE
3. DISCONNECT NEGATIVE ( −) TERMINAL CABLE
FROM BATTERY
4. DISCHARGE REFRIGERANT FROM REFRIGERA TION
SYSTEM
5. DISCONNECT DISCHARGE AND SUCTION HOSES
Remove the 2 bolts and disconnect the both hoses.
NOTICE:
Cap the open fittings immediately to keep the moisture or
dirt out of the system.
6. REMOVE ENGINE UNDER COVER
7. REMOVE DRIVE BELT (See page AC−16)
8. REMOVE COMPRESSOR
(a) Disconnect the connector.
(b) Remove the 4 bolts and pull the compressor upward.
9. REMOVE COMPRESSOR (See page AC−35 )
10. REMOVE PRESSURE PLATE
(a) Using SST and a socket wrench, remove the shaft bolt. Torque: 13.2 N·m (135 kgf·cm, 9 ft·lbf)
SST 07112 −76060
(b) Install a SST on the pressure plate. SST 07112 −66040
(c) Using SST and a socket wrench, remove the pressure plate.
SST 07112 −76060
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AC2R8−01
N04963
AC−38
−
AIR CONDITIONING COMPRESSOR AND MAGNETIC CLUTCH
1996 LAND CRUISER (RM451U)
REASSEMBLY
1. INSTALL COMPRESSOR
(a) Install the compressor with the 4 bolts. Torque: 25 N·m (250 kgf·cm, 18 ft·lbf)
(b) Connect the connector.
2. CONNECT DISCHARGE AND SUCTION HOSES Torque: 10 N·m (100 kgf·cm, 7 ft·lbf)
NOTICE:
Hoses should be connected immediately after the caps
have been removed.
HINT:
Lubricate 2 new O −rings with compressor oil and install the
hoses.
3. INSTALL AND INSPECT DRIVE BELT (See page AC−17 )
4. INSTALL ENGINE UNDER COVER
5. CONNECT NEGATIVE ( −) TERMINAL CABLE TO BAT-
TERY
6. EVACUATE AIR FROM REFRIGERATION SYSTEM
7. CHARGE SYSTEM WITH REFRIGERANT AND IN- SPECT FOR LEAKAGE OF REFRIGERANT
Specified amount:
850 ± 50 g (29.98 ± 1.76 oz.)
Using a gas leak detector, check for leakage of refrigerant.
If there is leakage, check the tightening torque at the joints.
8. INSPECT A/C OPERATION
Reassembly is in the reverse order of disassembly (See
page AC−35 ).
9. CHECK CLEARANCE OF MAGNETIC CLUTCH
(a) Set the dial indicator to the pressure plate of the magnetic
clutch.
(b) Connect the magnetic clutch lead wire to the positive (+) terminal of the battery.
(c) Check the clearance between the pressure plate and ro- tor when connecting the negative ( −) terminal to the bat-
tery.
Standard clearance:
0.5 ± 0.15 mm (0.020 ± 0.0059 in.)
If the clearance is not within the standard clearance, adjust the
clearance using shims to obtain the standard clearance. Shim Thickness:
0.1 mm (0.004 in.)
0.3 mm (0.012 in.)
0.5 mm (0.020 in.)
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BO37F−01
V00005
Clip RemoverPliers
Screwdriver Scraper
−
BODY CLIP
BO−1
1235
Author: Date:
1996 LAND CRUISER (RM451U)
CLIP
REPLACEMENT
The removal and installation methods of typical clips used in body parts ar\
e shown in the table below.
HINT:
If the clip is damaged during the operation, always replace it with a ne\
w clip.
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BO37N−01
BO2455
Cotton
TapePanel
Cover
−
BODY FRONT DOOR
BO−9
1996 LAND CRUISER (RM451U)
DISASSEMBLY
HINT:
Tape a screwdriver tip before using to pry parts.
1. REMOVE DOOR INSIDE HANDLE BEZEL
2. REMOVE ARMREST
3. REMOVE ARMREST PANEL BASE UPPER
4. REMOVE COURTESY LIGHT
5. REMOVE LOWER FRAME BRACKET GARNISH
6. REMOVE DOOR TRIM
(a) Remove the 3 screws from the door trim.
(b) Using a screwdriver, remove the clip and remove the trim
by pulling all of the trim up.
(c) Remove the 11 screws and armrest base from the door
trim.
(d) Remove the inner weatherstrip from the door trim.
(e) Remove the 8 screws and door pocket from the door trim.
7. REMOVE DOOR BELT MOULDING
Pry out the clip from the edge of the panel, and remove the
moulding .
8. REMOVE DOOR WEATHERSTRIP
NOTICE:
Do not pull strongly on the weatherstrip as it may tear.
9. REMOVE DOOR INSIDE HANDLE
10. REMOVE DOOR LOCK CONTROL RELAY
11. REMOVE SERVICE HOLE COVER
NOTICE:
Do not block the trim clip sealing with the tape.
12. REMOVE OUTSIDE REAR VIEW MIRROR
13. REMOVE DOOR GLASS RUN
14. REMOVE REAR LOWER FRAME
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BO37S−01
−
BODY REAR DOOR
BO−15
1996 LAND CRUISER (RM451U)
DISASSEMBLY
HINT:
Tape a screwdriver tip before using to pry parts.
1. REMOVE DOOR INSIDE HANDLE BEZEL
2. REMOVE DOOR SPEAKER COVER
3. REMOVE ASH TRAY
4. REMOVE ARMREST BASE UPPER
5. REMOVE ARMREST
6. REMOVE DOOR TRIM
(a) Remove the courtesy light.
(b) Remove the 3 screws from the door trim.
(c) Using a screwdriver, remove the clips and remove the trim
by pulling all of the trim up.
(d) Remove the inner weatherstrip from the door trim.
(e) Remove the 11 screws and the armrest base from the door trim.
7. REMOVE DOOR BELT MOULDING
Pry out the clip from the edge of the panel, and remove the
moulding.
8. REMOVE DOOR WEATHERSTRIP
NOTICE:
Do not pull strongly on the weatherstrip as it may tear.
9. REMOVE DOOR INSIDE HANDLE
10. REMOVE SERVICE HOLE COVER
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