Terminal TOYOTA LAND CRUISER 1996 J80 Workshop Manual

IN0CO−12
FI1066
Z11554
Seal Lock Adhesive
IN−4
−
INTRODUCTION REPAIR INSTRUCTIONS
4
Author: Date:
1996 LAND CRUISER (RM451U)
REPAIR INSTRUCTIONS
GENERAL INFORMATION
BASIC REPAIR HINT
(a) Use fender, seat and floor covers to keep the vehicle
clean and prevent damage.
(b) During disassembly, keep parts in the appropriate order to facilitate reassembly.
(c) Installation and removal of battery terminal: (1) Before performing electrical work, disconnect the
negative (−) terminal cable from the battery.
(2) If it is necessary to disconnect the battery for in- spection or repair, first disconnect the negative ( −)
terminal cable.
(3) When disconnecting the terminal cable, to prevent damage to battery terminal, loosen the cable nut
and raise the cable straight up without twisting or
prying it.
(4) Clean the battery terminals and cable ends with a clean shop rag. Do not scrape them with a file or oth-
er abrasive objects.
(5) Install the cable ends to the battery terminals after loosening the nut, and tighten the nut after installa-
tion. Do not use a hammer to tap the cable ends
onto the terminals.
(6) Be sure the cover for the positive (+) terminal is properly in place.
(d) Check hose and wiring connectors to make sure that they
are connected securely and correctly.
(e) Non−reusable parts (1) Always replace cotter pins, gaskets, O−rings, oilseals, etc. with new ones.
(2) Non−reusable parts are indicated in the component illustrations by the ” ” symbol.
(f) Precoated parts Precoated parts are bolts, nuts, etc. that are coated with
a seal lock adhesive at the factory.
(1) If a precoated part is retightened, loosened orcaused to move in any way, it must be recoated with
the specified adhesive.
(2) When reusing precoated parts, clean off the old
adhesive and dry with compressed air. Then apply
the specified seal lock adhesive to the bolt, nut or
threads.
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IN0253
WRONGCORRECT
IN0252
WRONGCORRECT
IN−6
−
INTRODUCTION REPAIR INSTRUCTIONS
6
Author: Date:
1996 LAND CRUISER (RM451U)
(k) Care must be taken when jacking up and supporting the
vehicle. Be sure to lift and support the vehicle at the prop-
er locations (See page IN−8).
Cancel the parking brake on the level place and
shift the transmission in Neutral (or N position).
When jacking up the front wheels of the vehicle at
first place stoppers behind the rear wheels.
When jacking up the rear wheels of the vehicle at
first place stoppers before the front wheels.
When either the front or rear wheels only should be
jacked up, set rigid racks and place stoppers in front
and behind the other wheels on the ground.
After the vehicle is jacked up, be sure to support it
on rigid racks . It is extremely dangerous to do any
work on a vehicle raised on a jack alone, even for
a small job that can be finished quickly.
(l) Observe the following precautions to avoid damage to the
following parts:
(1) Do not open the cover or case of the ECU unless absolutely necessary. (If the IC terminals are
touched, the IC may be destroyed by static electric-
ity.)
(2) To disconnect vacuum hoses, pull off the end, not the middle of the hose.
(3) To pull apart electrical connectors, pull on the con- nector itself, not the wires.
(4) Be careful not to drop electrical components, such
as sensors or relays. If they are dropped on a hard
floor, they should be replaced and not reused.
(5) When steam cleaning an engine, protect the elec- tronic components, air filter and emission −related
components from water.
(6) Never use an impact wrench to remove or install temperature switches or temperature sensors.
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IN0002
Example
−
INTRODUCTION REPAIR INSTRUCTIONS
IN−7
7
Author: Date:
1996 LAND CRUISER (RM451U)
(7) When checking continuity at the wire connector, in-
sert the tester probe carefully to prevent terminals
from bending.
(8) When using a vacuum gauge, never force the hose onto a connector that is too large. Use a step −down
adapter for adjustment. Once the hose has been
stretched, it may leak air.
(m) Installation and removal of vacuum hose: (1) When disconnecting vacuum hoses, use tags to
identify how they should be reconnected to.
(2) After completing a job, double check that the vacu-
um hoses are properly connected. A label under the
hood shows the proper layout.
(n) Unless otherwise stated, all resistance is measured at an
ambient temperature of 20° C (68°F). Because the resis-
tance may be outside specifications if measured at high
temperatures immediately after the vehicle has been run-
ning, measurement should be made when the engine has
cooled down.
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IN0IO−01
BO4111
Negative Cable
−
INTRODUCTION FOR ALL OF VEHICLES
IN−9
9
Author: Date:
1996 LAND CRUISER (RM451U)
FOR ALL OF VEHICLES
PRECAUTION
1. FOR VEHICLES EQUIPPED WITH SRS AIRBAG AND
SEAT BELT PRETENSIONER
(a) The LAND CRUISER is equipped with an SRS (Supple-
mental Restraint System), such as the driver airbag and
front passenger airbag assembly.
Failure to carry out service operations in the correct se-
quence could cause the supplemental restraint system to
unexpectedly deploy during servicing, possibly leading to
a serious accident.
Further, if a mistake is made in servicing the supplemental
restraint system, it is possible the SRS may fail to operate
when required. Before servicing (including removal or
installation of parts, inspection or replacement), be sure
to read the following items carefully, then follow the cor-
rect procedure described in this manual.
(b) GENERAL NOTICE (1) Malfunction symptoms of the supplemental re-straint system are difficult to confirm, so the diag-
nostic trouble codes become the most important
source of information when troubleshooting. When
troubleshooting the supplemental restraint system,
always inspect the diagnostic trouble codes before
disconnecting the battery (See page DI−240).
(2) Work must be started after 90 seconds from the
time the ignition switch is turned to the ”LOCK” posi-
tion and the negative ( −) terminal cable is discon-
nected from the battery.
(The supplemental restraint system is equipped
with a back−up power source so that if work is
started within 90 seconds of disconnecting the neg-
ative (−) terminal cable from the battery, the SRS
may deploy.)
When the negative (−) terminal cable is discon-
nected from the battery, memory of the clock and
audio systems will be cancelled. So before starting
work, make a record of the contents memorized by
the each memory system. Then when work is fin-
ished, reset the clock and audio systems as before.
To avoid erasing the memory of each memory sys-
tem, never use a back− up power supply from anoth-
er battery.
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BE2826
Cassette Tape Slot Cover
IN−16
−
INTRODUCTION FOR ALL OF VEHICLES
16
Author: Date:
1996 LAND CRUISER (RM451U)
6. FOR VEHICLES WITH AN AUDIO SYSTEM WITH
BUILT−IN ANTI−THEFT SYSTEM
Audio System displaying the sign ANTI −THEFT SYSTEM
shown on the left has a built −in anti −theft system which makes
the audio system soundless if stolen.
If the power source for the audio system is cut even once, the
anti0theft system operates so that even if the power source is
reconnected, the audio system will not produce any sound un-
less the ID number selected by the customer is input again. Ac-
cordingly, when performing repairs on vehicles equipped with
this system, before disconnecting the battery terminals or re-
moving the audio system the customer should be asked for the
ID number afterwards, or else a request made to the customer
to input the ID number. For the method to input the ID number
or cancel the anti−theft system, refer to the Owner’s Manual.
ANTI-THEFTSYSTEM
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V08425
LOCKKNK
E6 Connector
(a) Remove the glove compartment (See page SF− 68).
(b) Disconnect the E6 connector from the ECM.
INSPECTION PROCEDURE
Replace knock sensor.
1 Check continuity between terminal KNK of ECM connector and body ground.
OK:
Check knock sensor (See page SF−61).
Measure
the resistance between terminal KNK of the ECM connec-
tor and body ground.
Resistance: 1 MΩ or higher
Connector being checked is connected.
 Indicates the condition of the connector of ECU during the check.
PREPARATION:
CHECK:
2
Go to step 3.
OK OK
NG
 Indicates the position of the ignition switch during the check.
Check from the connector back side.
(with harness)
Ignition Switch LOCK (OFF) Ignition Switch START
LOCKIgnition Switch ONIgnition Switch ACC
START ON
ACC

 Indicates the place to check the voltage or resistance.
 Indicates the connector position to checked, from the front or back side.
Connector being checked is disconnected.
Check from the connector front side. (without harness)
In this case, care must be taken not to bend the terminals.
E6 Connector
KNK Wire Harness
E6 Connector
KNK
A00255
AB0117
A00265
Inspection Procedure
Use the inspection procedure to determine if
the circuit is normal or abnormal, and, if it is
abnormal, use it to determine whether the
problem is
located in the sensors, actuators,
wire harness or ECU.
−
INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMSIN−27
1996 LAND CRUISER (RM451U)
(2)
(2)
~
~
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FI0048
FI0047
FI0046
IN05X−13
IN−28−
INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMS
1996 LAND CRUISER (RM451U)
HOW TO USE THE DIAGNOSTIC
CHART AND INSPECTION
PROCEDURE
1. CONNECTOR CONNECTION AND TERMINAL IN- SPECTION
For troubleshooting, diagnostic trouble code charts or
problem symptom table are provided for each circuit with
detailed inspection procedures on the following pages.
When all the component parts, wire harnesses and con-
nectors of each circuit except the ECU are found to be
normal in troubleshooting, then it is determined that the
problem is in the ECU. Accordingly, if diagnosis is per-
formed without the problem symptoms occurring, refer to
Step 8 to replace the ECU. So always confirm that the
problem symptoms are occurring, or proceed with inspec-
tion while using the symptom simulation method.
The instructions ”Check wire harness and connector” and
”Check and replace ECU” which appear in the inspection
procedure, are common and applicable to all diagnostic
trouble codes. Follow the procedure outlined below
whenever these instructions appear.
OPEN CIRCUIT:
This could be due to a disconnected wire harness, faulty con-
tact in the connector, a connector terminal pulled out, etc.
HINT:
It is rarely the case that a wire is broken in the middle of
it. Most cases occur at the connector. In particular, care-
fully check the connectors of sensors and actuators
Faulty contact could be due to rusting of the connector
terminals, to foreign materials entering terminals or a de-
formation of connector terminals. Simply disconnecting
and reconnecting the connectors once changes the
condition of the connection and may result in a return to
normal operation. Therefore, in troubleshooting, if no ab-
normality is found in the wire harness and connector
check, but the problem disappears after the check, then
the cause is considered to be in the wire harness or con-
nectors.
SHORT CIRCUIT:
This could be due to a contact between wire harness and the
body ground or to a short circuit occurred inside the switch, etc.
HINT:
When there is a short circuit between the wire harness and body
ground, check thoroughly whether the wire harness is caught
in the body or is clamped properly.
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FI7187
IN0379
Sensor SideECU Side
IN0378
Sensor SideECU Side
IN0380
Sensor Side
ECU Side
IN0381
Pull Lightly
Looseness of Crimping
−
INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMSIN−29
1996 LAND CRUISER (RM451U)
2. CONNECTOR HANDLING
When inserting tester probes into a connector, insert them from
the rear of the connector. When necessary, use mini test leads.
For water resistant connectors which cannot be accessed from
behind, take good care not to deform the connector terminals.
3. CONTINUITY CHECK (OPEN CIRCUIT CHECK)
(a) Disconnect the connectors at both ECU and sensor
sides.
(b) Measure the resistance between the applicable terminals of the connectors.
Resistance: 1 Ω or less
HINT:
Measure the resistance while lightly shaking the wire harness
vertically and horizontally.
4. RESISTANCE CHECK (SHORT CIRCUIT CHECK)
(a) Disconnect the connectors on both ends.
(b) Measure the resistance between the applicable terminals of the connectors and body ground. Be sure to carry out
this check on the connectors on both ends.
Resistance: 1 MΩ or higher
HINT:
Measure the resistance while lightly shaking the wire harness
vertically and horizontally.
5. VISUAL CHECK AND CONTACT PRESSURE CHECK
(a) Disconnect the connectors at both ends.
(b) Check for rust or foreign material, etc. in the terminals of the connectors.
(c) Check crimped portions for looseness or damage and check that the terminals are secured in lock portion.
HINT:
The terminals should not come out when pulled lightly from the
back.
c:::::J
o0
c::=J
o0
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Z17004
Fig. 1
OPENECU
2
Sensor
22 2 1
111 AB
C
Z17005
Fig. 2
ECU
Sensor 21 A
B
C
1
1
22
B04722
Fig. 3
ECU
Sensor
21 A
C 1
1
221
2
1 B1
B2
IN−30−
INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMS
1996 LAND CRUISER (RM451U)
(d) Prepare a test male terminal and insert it in the female ter-
minal, then pull it out.
NOTICE:
When testing a gold −plated female terminal, always use a
gold −plated male terminal.
HINT:
When the test terminal is pulled out more easily than others,
there may be poor contact in that section.
6. CHECK OPEN CIRCUIT
For the open circuit in the wire harness in Fig. 1, perform ”(a)
Continuity Check” or ”(b) Voltage Check” to locate the section.
(a) Check the continuity. (1) Disconnect connectors ”A” and ”C” and measurethe resistance between them.
In the case of Fig. 2:
Between terminal 1 of connector ”A” and terminal 1
of connector ”C” → No continuity (open)
Between terminal 2 of connector ”A” and terminal 2
of connector ”C” → Continuity
Therefore, it is found out that there is an open circuit
between terminal 1 of connector ”A” and terminal 1
of connector ”C”.
(2) Disconnect connector ”B” and measure the resis- tance between the connectors.
In the case of Fig. 3:
Between terminal 1 of connector ”A” and terminal 1
of connector ”B1” → Continuity
Between terminal 1 of connector ”B2” and terminal
1 of connector ”C” → No continuity (open)
Therefore, it is found out that there is an open circuit
between terminal 1 of connector ”B2” and terminal
1 of connector ”C”.
BE4063
DO
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Z17007
Fig. 4Sensor 21 A
C
1
1
22B5V
5V
5V
0V
Z17008
Fig. 5
2
1 A
C
1
1
2 2
BSHORT
Z17009
Fig. 6
21 A
C
1
1
22
BSensor ECU
−
INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMSIN−31
1996 LAND CRUISER (RM451U)
(b) Check the voltage.
In a circuit in which voltage is applied (to the ECU connec-
tor terminal), an open circuit can be checked for by con-
ducting a voltage check.As shown in Fig. 4, with each connector still con-
nected, measure the voltage between body ground
and terminal 1 of connector ”A” at the ECU 5V out-
put terminal, terminal 1 of connector ”B”, and termi-
nal 1 of connector ”C”, in that order.
If the results are:
5V: Between Terminal 1 of connector ”A” and Body Ground
5V: Between Terminal 1 of connector ”B” and Body Ground
0V: Between Terminal 1 of connector ”C” and Body Ground
Then it is found out that there is an open circuit in the wire har-
ness between terminal 1 of ”B” and terminal 1 of ”C”.
7. CHECK SHORT CIRCUIT
If the wire harness is ground shorted as in Fig. 5, locate the sec-
tion by conducting a ”continuity check with ground”.
Check the continuity with ground. (1) Disconnect connectors ”A” and ”C” and measurethe resistance between terminal 1 and 2 of connec-
tor ”A” and body ground.
In the case of Fig. 6:
Between terminal 1 of connector ”A” and body
ground → Continuity (short)
Between terminal 2 of connector ”A” and body
ground → No continuity
Therefore, it is found out that there is a short circuit
between terminal 1 of connector ”A” and terminal 1
of connector ”C”.
BE4066
BE4067
BE4068
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