length TOYOTA LAND CRUISER 1996 J80 Workshop Manual

−
INTRODUCTION TERMS
IN−35
35
Author: Date:
1996 LAND CRUISER (RM451U)
H/B
Hatchback
H−FUSEHigh Current Fuse
HIHigh
HIDHigh Intensity Discharge (Head Lamp)
HPUHydraulic Power Unit
HSGHousing
HTHard Top
HWSHeated Windshield System
IACIdle Air Control
ICIntegrated circuit
IDIIndirect Diesel Injection
IFSIndependent Front Suspension
IGIgnition
IIAIntegrated Ignition Assembly
INIntake (Manifold, V
alve)
INTIntermittent
I/PInstrument Panel
IRSIndependent Rear Suspension
J/BJunction Block
J/CJunction Connector
KDKick−Down
LANLocal Area Network
LBLiftback
LCDLiquid Crystal Display
LEDLight Emitting Diode
LHLeft−Hand
LHDLeft−Hand Drive
L/H/WLength, Height, Width
LLCLong− Life Coolant
LNGLiquified Natural Gas
LOLow
LPGLiquified Petroleum Gas
LSDLimited Slip Dif ferential
LSP & PVLoad Sensing Proportioning And Bypass V alve
LSPVLoad Sensing Proportioning Valve
MAX.Maximum
M−FUSEMedium Current Fuse
MICMicrophone
MILMalfunction Indicator Lamp
MIN.Minimum
MPMultipurpose
MPXMultiplex Communication System
M/TManual Transmission (T ransaxle)
MTMount
MTGMounting
NNeutral
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Q07274
AT0T4−01
AT3168
SST
AT1362
Seal Breadth
2 − 3 mm
−
AUTOMATIC TRANSMISSION VALVE BODY ASSEMBLY
AT−7
791
Author: Date:
1996 LAND CRUISER (RM451U)
VALVE BODY ASSEMBLY
ON−VEHICLE REPAIR
1. DRAIN ATF
Torque: 20 N·m (205 kgf·cm, 15 ft·lbf)
2. REMOVE OIL PAN
NOTICE:
Some fluid will remain in the oil pan.
(a) Remove the 19 bolts. Torque: 7.4 N·m (75 kgf·cm, 65 in.·lbf)
(b) Install the blade of SST between the transmission case and oil pan, cut off applied sealer and then remove the oil
pan.
SST 09032−00100
NOTICE:
When removing the oil pan, be careful not to damage the oil
pan flange.
HINT:
At the time of installation, after removing all the old FIPG on the
contacting surface of the oil pan and transmission case, apply
new FIPG to the oil pan.(See page AT −1)
FIPG: Part No. 08826−00090, THREE BOND 1281 or
equivalent
3. WHEN REPLACING 3 SHIFT SOLENOID VALVES
(a) Disconnect the connectors from the solenoid valves.
(b) Remove the 3 solenoid valve mounting bolts. Torque: 10 N·m (100 kgf·cm, 7 ft·lbf)
(c) Remove the 3 solenoid valves.
HINT:
At the time of installation, replace the O−rings with new ones.
4. REMOVE OIL STRAINER
Remove the 4 bolts, and the oil strainer and gaskets. Torque: 10 N·m (100 kgf·cm, 7 ft·lbf)
NOTICE:
Be careful as some fluid will c ome out with the oil strainer.
Bolt length:
Bolt A: 16 mm (0.63 in.)
Bolt B: 20 mm (0.79 in.)
Bolt C: 28 mm (1.10 in.)
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Z11798
AB B
A
A
B B
B
AT1369
AT
−8
−
AUTOMATIC TRANSMISSION VALVE BODY ASSEMBLY
792
Author: Date:
1996 LAND CRUISER (RM451U)
HINT:
At the time of installation, replace the gaskets with new ones.
5. REMOVE OIL PIPE
Pry up both pipe ends with a large screwdriver and remove the
pipe.
NOTICE:
At time of the installation, make sure that the oil pipe or the
magnet do not interfere with the oil pan.
6. DISCONNECT CONNECTOR FROM EACH SOLENOID
VA LV E
7. REMOVE VALVE BODY
(a) Remove the 17 bolts. Torque:10 N·m (100 kgf·cm, 7 ft·lbf)
Bolt length:
Bolt A: 23 mm (0.91 in.)
Bolt B: 32 mm (1.26 in.)
(b) Disconnect the throttle cable from the cam.
(c) Remove the valve body.
NOTICE:
Be careful not to drop the check ball body and spring.
HINT:
At the time of installation, install the body together the check
ball body and spring and Align the groove of the manual valve
to the pin of the lever.
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BO0632
BO39M−01
BO0633
15°
45°
N10070
Full Belt Length
minus 200 mm
(7.87 in.)
−
BODY SEAT BELT
BO−93
1996 LAND CRUISER (RM451U)
SEAT BELT
INSPECTION
CAUTION:
Replace the seat belt assembly (outer belt, inner belt, bolts,
nuts or sill −bar) if it has been used in a severe impact. The
entire assembly should be replaced even if damage is not
obvious.
1. All seat belts: RUNNING TEST (IN SAFE AREA)
(a) Fasten the front seat belts.
(b) Drive the car at 10 mph (16 km/h) and make a very hard stop.
Check that the belt locks and cannot be extended at this
time.
HINT:
Conduct this test in a safe area. If the belt does not lock, remove
the belt mechanism assembly and conduct the following static
check. Also, whenever installing a new belt assembly, verify the
proper operation before installation.
2. Driver ’s seat belt (ELR): STATIC TEST
(a) Make sure that the belt locks when pulled out quickly.
(b) Remove the locking retractor assembly.
(c) Tilt the retractor slowly.
(d) Make sure that the belt can be pulled out at a tilt of 15 de-
grees or less, and cannot be pulled out at over 45 degrees
of tilt.
If a problem is found, replace the assembly.
3. Except driver’s seat belt (ALR/ELR):
STATIC TEST
(a) Make sure that the belt locks when pulled out quickly.
(b) Remove the locking retractor assembly.
(c) Pull out the whole belt and measure the length of the whole belt.
Then retract the belt slightly and pull it out again.
(d) Make sure that the belt cannot be extended further.
If a problem is found, replace the assembly.
(e) Retract the whole belt, then pull it out to the full length mi-
nus 200 mm (7.87 in.).
(f) Tilt the retractor slowly.
(g) Make sure that the belt can be pulled out at a tilt of 15 de-
grees or less, and cannot be pulled out at over 45 degrees
of tilt.
If a problem is found, replace the assembly.
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BR1CM-01
BR-14
-
BRAKE BRAKE MASTER CYLINDER
1996 LAND CRUISER (RM451U)
INSTALLATION
Installation is in the reverse order of removal (See page BR-9).
HINT:

Before installation, adjust length of brake booster push rod (See page \
BR-18).

After installation, fill brake reservoir with brake fluid, bleed brake s\
ystem (See page BR-4).

Check for leaks, check and adjust brake pedal (See page BR-6).
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BR1CQ−01
BR3976
SST
Gasket
R11347
SST
BR−20
−
BRAKE BRAKE BOOSTER ASSEMBLY
1996 LAND CRUISER (RM451U)
INSTALLATION
1. INSTALL BRAKE BOOSTER
(a) Install the booster and a new gasket.
(b) Install the clevis to the operating rod.
(c) Install and torque the booster installation nuts. Torque: 13 N·m (130 kgf·cm, 9 ft·lbf)
(d) Install the clevis pin into the clevis and brake pedal, and
install the clip to the clevis pin.
(e) Install the pedal return spring.
2. ADJUST LENGTH OF BOOSTER PUSH ROD
(a) Install a new gasket on the master cylinder.
(b) Set the SST on the gasket, and lower the pin until its tip slightly touches the piston.
SST 09737−00010
(c) Turn the SST upside down, and set it on the booster. SST 09737−00010
(d) Measure the clearance between the booster push rod and pin head (SST).
Clearance: 0 mm (0 in.)
(e) Adjust the booster push rod length until the push rod light-
ly touches the pin head.
3. INSTALL MASTER CYLINDER (See page BR−9 )
4. CONNECT VACUUM HOSE TO BRAKE BOOSTER
5. FILL BRAKE RESERVOIR WITH BRAKE FLUID AND
BLEED BRAKE SYSTEM (See page BR−4 )
6. CHECK FOR FLUID LEAKAGE
7. CHECK AND ADJUST BRAKE PEDAL (See page BR−6 )
8. DO OPERATIONAL CHECK (See page BR−17 )
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BR1DC−04
R05477
A
−
BRAKE LOAD SENSING PROPORTIONING AND BY− PASS
VALVE (LSP & BV)BR−45
1027
Author: Date:
1996 LAND CRUISER (RM451U)
ON−VEHICLE INSPECTION
1. SET REAR AXLE LOAD
Rear axle load (include vehicle weight):
1,330 kg (2,932 lb)
2. INSTALL LSPV GAUGE (SST) AND BLEED AIR SST 09709−29018
3. RAISE FRONT BRAKE PRESSURE TO 7,845 kPa (80 kgf/cm
2, 1,138 psi) AND CHECK REAR BRAKE PRES-
SURE
Rear brake pressure:
5,984 ± 589 kPa (61 ± 6 kgf/cm
2, 869± 86 psi)
HINT:
The brake pedal should not be depressed twice and/or returned
while setting to the specified pressure. Read the value of rear
pressure 2 seconds a fter adjusting the specified fluid pressure.
4. IF NECESSARY, ADJUST FLUID PRESSURE
(a) Disconnect the No.2 shackle from the shackle bracket.
(b) Adjust the length of the No.2 shackle turning it. Low pressure − Lengthen A.
High pressure − Shorten A
Initial set: 90 mm (3.54 in.)
Adjusting range: 84 − 96 mm (3.31 − 3.78 in.)
HINT:
One turn of the No.2 shackle changes the fluid pressure by
about 98.1 kPa (1.0 kgf/cm
2, 14.2 psi).
(c) In event the pressure cannot be adjusted by No.2 shackle, raise or lower the valve body.
Low pressure − Lower
High pressure − Raise
(d) Torque the 2 nuts. Torque: 13 N·m (130 kgf·cm, 9 ft·lbf)
(e) Adjust the length of the No.2 shackle again.
If it cannot be adjusted, inspect the valve housing.
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P13535
Length
Z04143
Positive (+)
Terminal
Rectifier
Terminal
Ohmmeter
Z04144
Negative (− )
Terminal
Ohmmeter
P00644
CH1026
−
CHARGING GENERATOR
CH−13
1996 LAND CRUISER (RM451U)
6. INSPECT EXPOSED BRUSH LENGTH
Using vernier calipers, measure the exposed brush length.
Standard exposed length: 10.5 mm (0.413 in.)
Minimum exposed length: 1.5 mm (0.059 in.)
If the exposed length is less than minimum, replace the brushes
and brush holder assembly.
7. INSPECT POSITIVE RECTIFIER
(a) Using an ohmmeter, connect one tester probe to the posi- tive (+) terminal and the other to each rectifier terminal.
(b) Reverse the polarity of the tester probes and repeat step (a).
(c) Check that one shows continuity and the other shows no
continuity.
If continuity is not as specified, replace the rectifier holder.
8. INSPECT NEGATIVE RECTIFIER
(a) Using an ohmmeter, connect one tester probe to each negative ( −) terminal and the other to each rectifier termi-
nal.
(b) Reverse the polarity of the tester probes and repeat step
(a).
(c) Check that one shows continuity and the other shows no continuity.
If continuity is not as specified, replace the rectifier holder.
9. INSPECT FRONT BEARING
Check that the bearing is not rough or worn.
10. INSPECT REAR BEARING
Check that the bearing is not rough or worn.
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P04776
146.6 mm16 Links
EM1EA−01
P03876
−
ENGINE MECHANICAL TIMING CHAIN
EM−17
1996 LAND CRUISER (RM451U)
INSPECTION
1. INSPECT TIMING CHAIN AND TIMING GEARS
(a) Measure the length of 16 links with the chain fully
stretched.
Maximum chain elongation: 146.6 mm (5.772 in.)
If the elongation is greater than maximum, replace the chain.
HINT:
Make the same measurements pulling at 3 or more places se-
lected at random.
(b) Wrap the chain around the timing gear.
(c) Using vernier calipers, measure the timing gear diameter with the chain.
NOTICE:
Vernier calipers must contact the chain rollers for measur-
ing.
Minimum gear diameter (w/Chain):
Camshaft126.0 mm (4.961 in.)
Crankshaft65.4 mm (2.575 in.)
If the diameter is less than minimum, replace the chain and
gears.
2. INSPECT CHAIN TENSIONER SLIPPER AND VIBRA-TION DAMPER
Measure the chain tensioner slipper and vibration damper
wears. Maximum wear: 1.0 mm (0.039 in.)
If the wear is greater than maximum, replace the slipper and/or
damper.
3. INSPECT OIL JET
Check the oil jet for damage or clogging.
If necessary, replace the oil jet.
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EM−22
−
ENGINE MECHANICAL TIMING CHAIN
1996 LAND CRUISER (RM451U)
(d) Engage the gear of the oil pump drive rotor with the gear
of the oil pump drive gear, and install the oil pump.
(e) Install the oil pump and drive belt adjusting bar with the 9 bolts and 2 nuts.
Torque: 21 N·m (210 kgf·cm, 15 ft·lbf)
HINT:
Each bolt length is indicated in the illustration.
Bolt A: 30 mm (1.18 in.)
Bolt B: 50 mm (1.97 in.)
Bolt C: 60 mm (2.38 in.)
(f) Remove the cord from the chain.
10. INSTALL DRIVE BELT IDLER PULLEY
Install the pulley with the bolt. Torque: 43 N·m (440 kgf·cm, 32 ft·lbf)
11. INSTALL CRANKSHAFT PULLEY
(a) Align the pulley set key with the key groove of the pulley, and slide on the pulley.
(b) Using SST, install and torque the pulley bolt.
SST 09213−58012, 09330 −00021
Torque: 412 N·m (4,200 kgf·cm, 304 ft·lbf)
12. INSTALL NO. 1 OIL PAN (See page LU−12)
13. INSTALL NO. 2 OIL PAN (See page LU−12)
14. INSTALL BOLTS HOLDING NO. 1 OIL PAN TO TRANS-
MISSION HOUSING
Install the 6 bolts. Torque: 72 N·m (730 kgf·cm, 53 ft·lbf)
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