water pump TOYOTA LAND CRUISER 1996 J80 Workshop Manual

IN0CI−02
IN−38
−
INTRODUCTION TERMS
1996 LAND CRUISER (RM451U)
GLOSSARY OF SAE AND TOYOTA TERMS
This glossary lists all SAE− J1930 terms and abbreviations used in this manual in compliance with SAE\
rec-
ommendations, as well as their TOYOTA equivalents.
SAE
ABBREVIATIONSSAE TERMSTOYOT A TERMS
( ) −−ABBREVIA TIONS
A/CAir ConditioningAir Conditioner
ACLAir CleanerAir Cleaner, A/CL
AIRSecondary Air InjectionAir Injection (AI)
APAccelerator Pedal−
B+Battery Positive Voltage+B, Battery Voltage
BAROBarometric PressureHAC
CACCharge Air CoolerIntercooler
CARBCarburetorCarburetor
CFIContinuous Fuel Injection−
CKPCrankshaft PositionCrank Angle
CLClosed LoopClosed Loop
CMPCamshaft PositionCam Angle
CPPClutch Pedal Position−
CTOXContinuous T rap Oxidizer−
CTPClosed Throttle PositionLL ON, Idle ON
DFIDirect Fuel Injection (Diesel)Direct Injection (DI)
DIDistributor Ignition−
DLC1
DLC2
DLC3Data Link Connector 1
Data Link Connector 2
Data Link Connector 31: Check Connector
2: Total Diagnosis Comunication Link (TDCL)
3: OBD II Diagnostic Connector
DTCDiagnostic Trouble CodeDiagnostic Code
DTMDiagnostic Test Mode−
ECLEngine Control Level−
ECMEngine Control ModuleEngine ECU (Electronic Control Unit)
ECTEngine Coolant T emperatureCoolant Temperature, Water Temperature (THW)
EEPROMElectrically Erasable Programmable Read Only Memory
Electrically Erasable Programmable Read Only Memory
(EEPROM),
Erasable Programmable Read Only Memory (EPROM)
EFEEarly Fuel EvaporationCold Mixture Heater (CMH), Heat Control Valve (HCV)
EGRExhaust Gas RecirculationExhaust Gas Recirculation (EGR)
EIElectronic IgnitionTOYOTA Distributorless Ignition (TDI)
EMEngine ModificationEngine Modification (EM)
EPROMErasable Programmable Read Only MemoryProgrammable Read Only Memory (PROM)
EVAPEvaporative EmissionEvaporative Emission Control (EVAP)
FCFan Control−
FEEPROMFlash Electrically Erasable Programmable
Read Only Memory−
FEPROMFlash Erasable Programmable Read Only Memory−
FFFlexible Fuel−
FPFuel PumpFuel Pump
GENGeneratorAlternator
GNDGroundGround (GND)
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C O 111−01
−
COOLING WATER PUMP
CO−3
698
Author: Date:
1996 LAND CRUISER (RM451U)
WATER PUMP
COMPONENTS
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CO112−01
CO−4
−
COOLING WATER PUMP
1996 LAND CRUISER (RM451U)
REMOVAL
1. DRAIN ENGINE COOLANT
2. DISCONNECT NO.3 WATER BYPASS HOSE
3. DISCONNECT RADIATOR INLET HOSE
4. REMOVE DRIVE BELTS, FAN WITH FLUID COU- PLING, WATER PUMP PULLEY AND FAN SHROUD
(a) Stretch the belts and loosen the water pump pulley mounting nuts.
(b) Loosen the lock, pivot and adjusting bolts of the genera- tor, and remove the drive belts.
(c) Disconnect the oil cooler hose from the clamp on the fan shroud.
(d) Remove the 2 bolts holding the fan shroud to the radiator.
(e) Remove the 4 water pump pulley mounting nuts.
(f) Pull out the fan with fluid coupling, water pump pulley and
fan shroud.
(g) Remove the fan from the fluid coupling.
5. REMOVE WATER PUMP
Remove the 4 bolts, 2 nuts, water pump and gasket.
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CO113−04
−
COOLING WATER PUMP
CO−5
1996 LAND CRUISER (RM451U)
INSPECTION
1. INSPECT WATER PUMP
(a) Visually check the air hole and water hole for coolant leak-
age.
If leakage is found, replace the water pump.
(b) Turn the pulley seat and check that the water pump bear- ing moves smoothly and quietly.
If necessary, replace the water pump.
2. INSPECT FLUID COUPLING
Check the fluid coupling for damage and silicon oil leakage.
If necessary, replace the fluid coupling.
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CO114−02
CO−6
−
COOLING WATER PUMP
1996 LAND CRUISER (RM451U)
INSTALLATION
1. INSTALL WATER PUMP
Install a new gasket and the water pump with the 4 bolts and 2
nuts. Torque: 21 N·m (210 kgf·cm, 15 ft·lbf)
2. INSTALL WATER PUMP PULLEY, FAN SHROUD, FAN WITH FLUID COUPLING AND DRIVE BELTS
(a) Install fan to the fluid coupling.
(b) Place the fan with fluid coupling, water pump pulley and fan shroud in position.
(c) Temporarily install the fan pulley mounting nuts.
(d) Install the fan shroud with the 2 bolts. Torque: 5.0 N·m (50 kgf·cm, 43 in.·lbf)
(e) Connect the oil cooler hose to the clamp on the fan
shroud.
(f) Install the drive belts with the adjusting bolt and pivot bolt.
(g) Stretch the belts tight and tighten the 4 water pump pulley mounting nuts.
(h) Adjust the drive belts (See page CH−2 ).
3. CONNECT NO.3 WATER BYPASS HOSE
4. CONNECT RADIATOR INLET HOSE
5. FILL RADIATOR WITH ENGINE COOLANT
6. START ENGINE AND CHECK FOR LEAKS
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CO116−01
CO−10
−
COOLING THERMOSTAT
1996 LAND CRUISER (RM451U)
INSTALLATION
1. PLACE THERMOSTAT IN WATER PUMP
(a) Install a new gasket on to the thermostat.
(b) Align the thermostat jiggle valve with the protrusion of the
water inlet housing, and insert the thermostat in the water
inlet housing.
HINT:
The jiggle valve may be set within 15 ° of either side of the pre-
scribed position.
2. INSTALL WATER INLET
Install the water inlet with the 3 nuts. Torque: 21 N·m (210 kgf·cm, 15 ft·lbf)
3. FILL RADIATOR WITH ENGINE COOLANT
4. START ENGINE AND CHECK FOR LEAKS
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CO0IZ−03
Z02362
CO−12
−
COOLING RADIATOR
1996 LAND CRUISER (RM451U)
ON−VEHICLE INSPECTION
1. REMOVE RADIATOR TANK CAP
CAUTION:
To avoid the danger of being burned, do not remove the ra-
diator cap while the engine and radiator are still hot, as fluid
and steam can be blown out under pressure.
2. INSPECT RADIATOR CAP
NOTICE:
If the radiator cap has contaminations, always rinse it with
water. Before using a radiator cap tester, wet the relief
valve and pressure valve with coolant or water.
Using a radiator cap tester, pump the tester and measure the
relief valve opening pressure. Standard opening pressure:
74 − 103 kPa
(0.75 − 1.05 kgf/cm
2, 10.7 − 14.9 psi)
Minimum opening pressure:
59 kPa (0.6 kgf/cm
2, 8.5 psi)
HINT:
Use the tester’s maximum reading as the opening pressure.
If the opening pressure is less than minimum, replace the radia-
tor cap.
3. INSPECT COOLING SYSTEM FOR LEAKS
(a) Fill the radiator with coolant and attach a radiator cap tes-
ter.
(b) Warm up the engine.
(c) Pump it to 118 kPa (1.2 kgf/cm
2, 17.1 psi), and check that
the pressure does not drop.
If the pressure drops, check the hoses, radiator or water pump
for leaks. If no external leaks are found, check the heater core,
cylinder block and head.
4. REINSTALL RADIATOR CAP
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CO117−02
CO−14
−
COOLING RADIATOR
1996 LAND CRUISER (RM451U)
REMOVAL
1. DRAIN ENGINE COOLANT
2. REMOVE BATTERY AND BATTERY TRAY
(a) Disconnect the battery cables.
(b) Remove the nuts, hold −down clamp and battery.
(c) Remove the bolt and disconnect the ground strap.
(d) Remove the 5 bolts and battery tray.
3. REMOVE RADIATOR GRILLE
Remove the 5 screws, clip and radiator grille.
4. DISCONNECT NO.3 WATER BYPASS HOSE
5. DISCONNECT RADIATOR INLET HOSE
6. DISCONNECT RADIATOR RESERVOIR HOSE
7. REMOVE RADIATOR
(a) Stretch the belts and loosen the water pump pulley mounting nuts.
(b) Loosen the lock, pivot and adjusting bolts of the genera- tor, and remove the drive belts.
(c) Disconnect the oil cooler hose from the clamp on the fan shroud.
(d) Remove the 2 bolts holding the fan shroud to the radiator.
(e) Remove the 4 water pump pulley mounting nuts.
(f) Pull out the fan with fluid coupling, water pump pulley and
fan shroud.
8. DISCONNECT A/T OIL COOLER HOSES
9. DISCONNECT RADIATOR OUTLET HOSE
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CO118−01
CO−16
−
COOLING RADIATOR
1996 LAND CRUISER (RM451U)
INSTALLATION
1. INSTALL RADIATOR
(a) Install the 2 radiator brackets with the 4 nuts. Torque: 12 N·m (120 kgf·cm, 9 ft·lbf)
(b) Install the radiator with the 2 bolts and 2 nuts. Torque:
Bolt: 18 N·m (185 kgf·cm, 13 ft·lbf)
Nut: 12 N·m (120 kgf·cm, 9 ft·lbf)
2. CONNECT A/T OIL COOLER HOSES
3. CONNECT RADIATOR OUTLET HOSE
4. INSTALL WATER PUMP PULLEY, FAN SHROUD, FAN WITH FLUID COUPLING AND DRIVE BELTS
(a) Place the fan with fluid coupling, water pump pulley and fan shroud in position.
(b) Temporarily install the fan pulley mounting nuts.
(c) Install the fan shroud with the 2 bolts. Torque: 5.0 N·m (50 kgf·cm, 43 in.·lbf)
(d) Connect the oil cooler hose to the clamp on the fan
shroud.
(e) Install the drive belts with the adjusting bolt and pivot bolt.
(f) Stretch the belts tight and tighten the 4 water pump pulley mounting nuts.
(g) Adjust the drive belts (See page CH−2 ).
5. CONNECT RADIATOR RESERVOIR HOSE
6. CONNECT RADIATOR INLET HOSE
7. CONNECT NO.3 WATER BYPASS HOSE
8. INSTALL RADIATOR GRILLE
Install the radiator grille with the 5 screws and clip.
9. INSTALL BATTERY AND BATTERY TRAY
(a) Install the battery tray with the 5 bolts.
(b) Connect the ground strap with the bolt.
(c) Install the battery with the hold−down clamp and nuts.
(d) Connect the battery cables.
10. FILL RADIATOR WITH ENGINE COOLANT
11. START ENGINE AND CHECK FOR LEAKS
12. CHECK AUTOMATIC TRANSMISSION FLUID LEVEL
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EM1E9−01
−
ENGINE MECHANICAL TIMING CHAIN
EM−13
1996 LAND CRUISER (RM451U)
REMOVAL
1. DRAIN ENGINE OIL
2. DRAIN ENGINE COOLANT
3. REMOVE ENGINE UNDER COVER
4. REMOVE RADIATOR (See page CO−14 )
5. DISCONNECT A/C COMPRESSOR AND BRACKET
(a) Loosen the idler pulley nut and adjusting bolt, and remove
the drive belt.
(b) Remove the 4 mounting bolts, and disconnect the com- pressor from the bracket.
HINT:
Put aside the compressor, and suspend it.
(c) Remove the 5 bolts and A/C compressor bracket.
6. REMOVE RADIATOR PIPE
(a) Disconnect the No. 2 radiator hose from the water inlet.
(b) Remove the 2 nuts and radiator pipe.
7. REMOVE WATER PUMP
Remove the 4 bolts, 2 nuts, water pump and gasket.
8. REMOVE CYLINDER HEAD (See page EM−28 )
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