service TOYOTA LAND CRUISER 1996 J80 Workshop Manual
[x] Cancel search | Manufacturer: TOYOTA, Model Year: 1996, Model line: LAND CRUISER, Model: TOYOTA LAND CRUISER 1996 J80Pages: 1399, PDF Size: 41.35 MB
Page 2 of 1399
IN00U−36
N17080
Filler Cap
Float
Reservoir Grommet
Clip
Slotted Spring Pin
: Specified torque
Non− reusable partCylinder
Piston
Push Rod
Washer
Snap Ring
Boot
Gasket
Lock Nut
Clevis Pin
Clevis
N·m (kgf·cm, ft·lbf)
12 (120, 9)
15 (155, 11)
−
INTRODUCTION HOW TO USE THIS MANUAL
IN−1
1
Author: Date:
1996 LAND CRUISER (RM451U)
HOW TO USE THIS MANUAL
GENERAL INFORMATION
1. INDEX
An INDEX is provided on the first page of each section to guide you to the item to be repaired. To assist you
in finding your way through the manual, the section title and major headin\
g are given at the top of every page.
2. PRECAUTION
At the beginning of each section, a PRECAUTION is given that pertains to al\
l repair operations contained
in that section.
Read these precautions before starting any repair task.
3. TROUBLESHOOTING
TROUBLESHOOTING tables are included for each system to help you diagnose\
the problem and find the
cause. The fundamentals of how to proceed with troubleshooting are described o\
n page IN−18.
Be sure to read this before performing troubleshooting.
4. PREPARATION
Preparation lists the SST (Special Service Tools), recommended tools, equipment, lubricant and SSM (Spe-
cial Service Materials) which should be prepared before beginning the o\
peration and explains the purpose
of each one.
5. REPAIR PROCEDURES
Most repair operations begin with an overview illustration. It identifies the components and shows how the
parts fit together.
Example:
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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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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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BE1367
Medium Current Fuse and High Current Fuse
Equal Amperage Rating
V00076
Abbreviation
Part Name
Symbol
Illustration
FUSE
MEDIUM CURRENT FUSE
HIGH CURRENT FUSE
FUSIBLE LINK
CIRCUIT BREAKER FUSE
M−FUSE
H−FUSE
FL
CB
−
INTRODUCTION REPAIR INSTRUCTIONS
IN−5
5
Author: Date:
1996 LAND CRUISER (RM451U)
(3) Precoated parts are indicated in the component il-
lustrations by the ” ” symbol.
(g) When necessary, use a sealer on gaskets to prevent
leaks.
(h) Carefully observe all specifications for bolt tightening torques. Always use a torque wrench.
(i) Use of special service tools (SST) and special service ma-
terials (SSM) may be required, depending on the nature
of the repair. Be sure to use SST and SSM where speci-
fied and follow the proper work procedure. A list of SST
and SSM can be found in Preparation section in this
manual.
(j) When replacing fuses, be sure the new fuse has the cor- rect amperage rating. DO NOT exceed the rating or use
one with a lower rating.
~
iJ<>~o~BE5594 IN0365
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BE5595IN0366
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BE5596IN0367
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BE5597IN0367
~BE5598SN0368
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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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IN04S−30
−
INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMSIN−17
17
Author: Date:
1996 LAND CRUISER (RM451U)
HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS
GENERAL INFORMATION
A large number of ECU controlled systems are used in the LAND CRUISER. In general, the ECU controlled
system is considered to be a very intricate system requiring a high level of t\
echnical knowledge and expert
skill to troubleshoot. However, the fact is that if you proceed to inspect the circuits one by one, trou\
bleshoot-
ing of these systems is not complex. If you have adequate understanding of the system and a basic knowl-
edge of electricity, accurate diagnosis and necessary repair can be performed to locate and fix the pr\
oblem.
This manual is designed through emphasis of the above standpoint to help service techn\
icians perform ac-
curate and effective troubleshooting, and is compiled for the following major ECU con\
trolled systems:
The troubleshooting procedure and how to make use of it are described on\
the following pages.
SystemPage
1. EngineDI−1
2. Automatic TransmissionDI−129
3. Anti− Lock Brake SystemDI−188
4. Supplemental Restraint SystemDI−238
5. Cruise Control SystemDI−284
FOR USING OBD II SCAN TOOL OR TOYOTA HAND−HELD TESTER
Before using the scan tool or tester, the scan tool’ s instruction book or tester’s operator manual should
be read thoroughly.
If the scan tool or tester cannot communicate with ECU controlled systems \
when you have connected
the cable of the scan tool or tester to DLC3, turned the ignition switch\
ON and operated the scan tool,
there is a problem on the vehicle side or tool side.
(1) If communication is normal when the tool is connected to another vehicle, \
inspect the diagnosis data link line (Bus line) or ECU power circuit of the vehicle.
(2) If communication is still not possible when the tool is connected to anoth\
er vehicle, the problem is probably in the tool itself, so perform the Self Test procedures outline in the Tester Operator’s
Manual.
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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−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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AC−2
−
AIR CONDITIONING AIR CONDITIONING SYSTEM
1329
Author: Date:
1996 LAND CRUISER (RM451U)
9. SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
The LAND CRUISER is equipped with an SRS (Spplemental
Restraint System)such as the driver airbag and passenger air
bag. Failure to carry out service operations in the correct se-
quence could cause the SRS to unexpectedly deployed during
servicing, possibly leading to a serious accident. Further, if a
mistake is made in servicing the SRS, it is possible the SRS may
fail to operate when required. Before servicing (including re-
moval or installation of parts, inspection or replacement), be
sure to read the following item carefully, then follow the correct
procedure described in the repair manual.
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N13795
Quick Disconnect
AdapterCharging
Service Valve Hose
AC2QE−01
N13794
Vacuum Pump
Vacuum Pump Adapter
N13791
Low Pressure
Service Valve
Vacuum Pump Adapter
High Pressure
Service Valve Manifold
Gauge
Set
−
AIR CONDITIONING AIR CONDITIONING SYSTEM
AC−11
1996 LAND CRUISER (RM451U)
EVACUATING
1. CONNECT QUICK DISCONNECT ADAPTERS TO
CHARGING HOSES
2. REMOVE CAPS FROM SERVICE VALVES ON RE- FRIGERANT LINES
3. INSTALL MANIFOLD GAUGE SET
(a) Close both hand valves of manifold gauge set.
(b) Connect the quick disconnect adapters to the service valves.
4. EVACUATE AIR FROM REFRIGERATION SYSTEM
(a) Connect the vacuum pump adapter to the vacuum pump.
(b) Connect the center hose of the manifold gauge set to the vacuum pump adapter.
(c) Open both the high and low hand valves and run the vacu-
um pump.
(d) After 10 minutes or more, check that the low pressure
gauge indicates 750 mmHg (30 in.Hg) or more.
HINT:
If the reading is not 750 mmHg (30 in.Hg) or more, close both
hand valves of manifold gauge set and stop the vacuum pump.
Check the system for leaks and repair as necessary.
(e) Close both the high and low hand valves and stop the vac-
uum pump.
(f) Leave the system in this condition for 5 minutes or more and check that there is no gauge indicator.
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