power steering TOYOTA LAND CRUISER 1996 J80 Workshop Manual

−
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−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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−
INTRODUCTION TERMS
IN−37
37
Author: Date:
1996 LAND CRUISER (RM451U)
TC
Turbocharger
TCCSTOYOTA
Computer− Controlled System
TCVTiming Control V alve
TDCTop Dead Center
TEMP.Temperature
TEMSTOYOTA Electronic Modulated Suspension
TISTotal Information System For Vehicle Development
T/MTransmission
TMCTOYOTA Motor Corporation
TMMKTOYOTA Motor Manufacturing Kentucky, Inc.
TRACTraction Control System
TURBOTurbocharge
U/DUnderdrive
U/SUndersize
VCVVacuum Control V alve
VENTVentilator
VINVehicle Identification Number
VPSVariable Power Steering
VSCVehicle Skid Control
VSVVacuum Switching Valve
VTVVacuum Transmitting V alve
w/With
WGNWagon
W/HWire Harness
w/oWithout
1stFirst
2ndSecond
2WDTwo Wheel Drive Vehicle (4x2)
4WDFour Wheel Drive Vehicle (4x4)
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−
INTRODUCTION TERMS
IN−39
1996 LAND CRUISER (RM451U)
HO2S
Heated Oxygen SensorHeated Oxygen Sensor (HO2S)
IACIdle Air ControlIdle Speed Control (ISC)
IATIntake Air TemperatureIntake or Inlet Air T
emperature
ICMIgnition Control Module−
IFIIndirect Fuel InjectionIndirect Injection (IDL)
IFSInertia Fuel−Shutoff−
ISCIdle Speed Control−
KSKnock SensorKnock Sensor
MAFMass Air FlowAir Flow Meter
MAPManifold Absolute PressureManifold Pressure
Intake V acuum
MCMixture Control
Electric Bleed Air Control Valve (EBCV)
Mixture Control Valve (MCV)
Electric Air Control Valve (EACV)
MDPManifold Dif ferential Pressure−
MFIMultiport Fuel InjectionElectronic Fuel Injection (EFI)
MILMalfunction Indicator LampCheck Engine Lamp
MSTManifold Surface T emperature−
MVZManifold Vacuum Zone−
NVRAMNon−Volatile Random Access Memory−
O2SOxygen SensorOxygen Sensor, O2 Sensor (O2S)
OBDOn−Board DiagnosticOn− Board Diagnostic System (OBD)
OCOxidation Catalytic ConverterOxidation Catalyst Convert (OC), CCo
OPOpen LoopOpen Loop
PAIRPulsed Secondary Air InjectionAir Suction (AS)
PCMPowertrain Control Module−
PNPPark/Neutral Position−
PROMProgrammable Read Only Memory−
PSPPower Steering Pressure−
PTOXPeriodic Trap OxidizerDiesel Particulate Filter (DPF)
Diesel Particulate Trap (DPT)
RAMRandom Access MemoryRandom Access Memory (RAM)
RMRelay Module−
ROMRead Only MemoryRead Only Memory (ROM)
RPMEngine SpeedEngine Speed
SCSuperchargerSupercharger
SCBSupercharger BypassE−ABV
SFISequential Multiport Fuel InjectionElectronic Fuel Injection (EFI), Sequential Injection
SPLSmoke Puff Limiter−
SRIService Reminder Indicator−
SRTSystem Readiness Test−
STScan Tool−
TBThrottle BodyThrottle Body
TBIThrottle Body Fuel InjectionSingle Point Injection
Central Fuel Injection (Ci)
TCTurbochargerTurbocharger
TCCTorque Converter ClutchTorque Converter
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CH0EP−01
CH−8
−
CHARGING GENERATOR
1996 LAND CRUISER (RM451U)
REMOVAL
1. REMOVE BATTERY AND BATTERY TRAY
2. DISCONNECT POWER STEERING (PS) RESERVOIR TANK
3. REMOVE DRIVE BELTS
(a) Loosen the lock bolt, pivot bolt and adjusting bolt.
(b) Remove the 2 drive belts.
4. REMOVE GENERATOR
(a) Disconnect the generator connector.
(b) Remove the rubber cap and nut, and disconnect the gen-
erator wire.
(c) Disconnect the generator wire clamp from the generator.
(d) Remove the lock bolt, bolt, nut and drive belt adjusting bar.
(e) Remove the pivot bolt and generator.
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CH06N−03
−
CHARGING GENERATOR
CH−19
1996 LAND CRUISER (RM451U)
INSTALLATION
1. INSTALL GENERATOR
(a) Mount generator on the generator bracket with the pivot
bolt. Do not tighten the bolt yet.
(b) Install the drive belt adjusting bar with the bolt and nut. Torque: 21 N·m (210 kgf·cm, 15 ft·lbf)
(c) Temporarily install the lock bolt.
(d) Connect the generator connector.
(e) Connect the generator wire with the nut and rubber cap.
(f) Connect the generator wire clamp to the generator.
2. INSTALL DRIVE BELTS
(a) Install the drive belts.
(b) Adjust the drive belt with the adjusting bolt (See page
CH−2 ).
(c) Tighten the pivot and adjusting lock bolts. Torque:
Pivot bolt: 59 N·m (600 kgf·cm, 43 ft·lbf)
Lock bolt: 21 N·m (210 kgf·cm, 15 ft·lbf)
3. CONNECT POWER STEERING (PS) RESERVOIR TANK
4. INSTALL BATTERY TRAY AND BATTERY
5. PERFORM ON−VEHICLE INSPECTION (See page CH−2 )
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DI5Q3−02
−
DIAGNOSTICS SUPPLEMENTAL RESTRAINT SYSTEM
DI−243
1996 LAND CRUISER (RM451U)
DIAGNOSTIC TROUBLE CODE CHART
If a malfunction code is displayed during the DTC check, the circuit listed for that code in t\
he table below
(Proceed to the page given for that circuit.).
DTC No.
(See Page)Detection ItemTrouble AreaSRS
Warning Light
Normal
( DI−271 )System normal−OFF
Source voltage dropBattery
 Airbag sensor assemblyON
11
( DI−247 )
Short in squib circuit (to ground)Steering wheel pad (D squib)
 Front passenger airbag assembly (P squib )
 Spiral cable
 Airbag sensor assembly
 Wire harness
ON
12
( DI−254 )
Short in squib circuit (to B+)Steering wheel pad (D squib)
 Front passenger airbag assembly (P squib)
 Spiral cable
 Airbag sensor assembly
 Wire harness
ON
14
( DI−260 )
Open in D squib circuitSteering wheel pad (D squib)
 Spiral cable
 Airbag sensor assembly
 Wire harness
ON
31
( DI−265 )Airbag sensor assembly malfunctionAirbag sensor assemblyON
54
( DI−267 )Open in P squib circuitFront passenger airbag assembly (P squib)
 Airbag sensor assembly
 Wire harness
ON
HINT:
When the SRS warning light remains lit up and the DTC is the normal code\
, this means a source drop
voltage.
This malfunction is not stored in memory by the airbag sensor assembly a\
nd if the power source volt-
age returns to normal, the SRS warning light will automatically go out.
When 2 or more codes are indicated, the codes will be displayed in numer\
al order starting from the
lowest numbered code.
If a code not listed on the chart is displayed, the airbag sensor assemb\
ly is faulty.
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MA02R−04
MA−4
−
MAINTENANCE UNDER HOOD
44
Author: Date:
1996 LAND CRUISER (RM451U)
UNDER HOOD
GENERAL MAINTENANCE
1. GENERAL NOTICE
Maintenance items may vary from country to country. Check the owner’s manual supplement in which
the maintenance schedule is shown.
Every service item in the periodic maintenance schedule must be performe\
d.
Periodic maintenance service must be performed according to whichever interval in\
the periodic main-
tenance schedule occurs first, the odometer reading (miles) or the time inter\
val (months).
Maintenance service after the last period should be performed at the same interval \
as before unless
otherwise noted.
Failure to do even one item can cause the engine to run poorly and incre\
ase exhaust emissions.
2. WINDSHIELD WASHER FLUID
Check that there is sufficient fluid in the tank.
3. ENGINE COOLANT LEVEL Check that the coolant level is between the FULL and LOW lines on the se\
e −through reservoir.
4. RADIATOR AND HOSES
(a) Check that the front of the radiator is clean and not blocked with leave\
s, dirt or bugs.
(b) Check the hoses for cracks, kinks, rot or loose connections.
5. BATTERY ELECTROLYTE LEVEL
Check that the electrolyte level of all battery cells is between the upp\
er and lower level lines on the case.
If level is low, add distilled water only.
6. BRAKE FLUID LEVELS
Check that the brake fluid level is near the upper level line on the see\
−through reservoir.
7. ENGINE DRIVE BELTS
Check drive belt for fraying, cracks, wear or oiliness.
8. ENGINE OIL LEVEL
Check the level on the dipstick with the engine turned off.
9. POWER STEERING FLUID LEVEL
(a) Check the level on the dipstick.
(b) The level should be in the HOT or COLD range depending on the fluid temp\
erature.
10. AUTOMATIC TRANSMISSION FLUID LEVEL
(a) Park the vehicle on a level surface.
(b) With the engine idling and the parking and foot brake applied, shift the sel\
ector into all positions from the P to L, and then shift into the P.
(c) Pull out the dipstick and wipe off the fluid with a clean rag. Re −insert the dipstick fully and check that
the fluid level is in the HOT range.
(d) Do this check with the fluid at normal driving temperature (70 − 80°C (158 − 176° F)).
HINT:
Wait about 30 minutes before checking the fluid level after extended driving\
at high speeds in hot weather,
driving in heavy traffic or with a trailer.
11. EXHAUST SYSTEM
Visually inspect for cracks, holes or loose supports.
If any change in the sound of the exhaust or smell of the exhaust fumes is\
noticed, have the cause located
and corrected.
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PP3KU−01
−
PREPARATION SFI
PP−11
60
Author: Date:
1996 LAND CRUISER (RM451U)
SFI
SST (Special Service Tools)
09268−41047Injection Measuring Tool Set
(09268−41091)NO.7 Union
(90405−09015)No.1 Union
09268−45012EFI Fuel Pressure Gauge
09631−22020Power Steering Hose Nut
14 x 17 mm Wrench SetFuel line flare nut
09816−30010Oil Pressure Switch SocketKnock sensor
09842−30070Wiring ”F” EFI Inspection
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PP3KM−01
PP−56
−
PREPARATION STEERING
105
Author: Date:
1996 LAND CRUISER (RM451U)
STEERING
SST (Special Service Tools)
09527−10011Rear Axle Shaft Bearing RemoverPS vane pump
09610−55012Pitman Arm PullerSteering linkage
09611−22012Tie Rod End PullerSteering linkage
09616−00011Steering Worm Bearing Adjusting
SocketPS gear
09628−62011Ball Joint PullerSteering linkage
09630−00014Power Steering Gear Housing
Overhaul Tool Set
(09631−00051)No.3 WrenchPS gear
(09631−00121)Teflon Ring FormerPS gear
(09631−00142)Overhaul StandPS gear
09631−10030Oil Seal RemoverPS vane pump
09631−22020Power Steering Hose Nut
14 x 17 mm Wrench SetPS gear
09640−10010Power Steering Pressure Gauge
Set
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