1996 TOYOTA LAND CRUISER Workshop Manual

EM−72
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ENGINE MECHANICAL ENGINE UNIT
1996 LAND CRUISER (RM451U)
24. REMOVE FRONT AND REAR PROPELLER SHAFTS
(a) Put matchmarks on the flanges.
(b) Remove the 4 bolts and nuts.
(c) Remove the 4 nuts.
(d) Remove the propeller shaft.
25. REMOVE TRANSFER SHIFT LEVER
(a) Remove the nut and transmission control rod.
(b) Remove the transfer shift lever knob.
(c) Remove 4 screws.
(d) Lift up the console slightly in order to disconnect the con-
nector.
(e) Remove the console.
(f) Remove the 3 bolts and console box.
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ENGINE MECHANICAL ENGINE UNIT
EM−73
1996 LAND CRUISER (RM451U)
(g) Disconnect the 3 connectors.
(h) Remove the 10 bolts and the transfer shift lever boot and
transmission shift lever assembly.
(i) Pull out the pin and disconnect the shift rod.
(j) Remove the 4 bolts, hose clamp and the transfer shift le- ver.
26. REMOVE FRONT EXHAUST PIPE
(a) Disconnect the heated oxygen sensor connector.
(b) Remove the 2 nuts and 2 bolts holding the front exhaust pipe to the rear TWC.
(c) Disconnect the front exhaust pipe, and remove the gas- ket.
(d) Loosen the clamp bolt and disconnect the clamp from the
No.1 support bracket.
(e) Remove the 2 bolts and No. 1 support bracket.
(f) Remove the 4 nuts, front exhaust pipe and 2 gaskets.
27. DISCONNECT GROUND STRAP FROM HEAT INSULA-
TOR
28. PLACE JACK UNDER TRANSMISSION
Be sure to put a wooden block between the jack and the trans-
mission oil pan to prevent damage.
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EM−74
−
ENGINE MECHANICAL ENGINE UNIT
1996 LAND CRUISER (RM451U)
29. REMOVE FRAME CROSSMEMBER
(a) Remove the 2 nuts holding the crossmember to the en-
gine rear mounting insulator.
(b) Remove the 8 bolts and crossmember.
30. REMOVE ENGINE WITH TRANSMISSION
(a) Attach the engine hoist chain to the 2 engine hangers.
(b) Remove the 2 nuts holding the engine front mounting in- sulators to the frame.
(c) Lift the engine with transmission out of the vehicle slowly
and carefully.
NOTICE:
Make sure that the engine is clear of all wiring and hoses.
(d) Place the engine and transmission assembly onto the stand.
31. REMOVE OIL DIPSTICK GUIDE FOR TRANSMISSION
(a) Disconnect the 2 breather hoses.
(b) Remove the 2 mounting bolts.
(c) Pull out the dipstick guide and dipstick from the transmis- sion.
(d) Remove the O−ring from the dipstick guide.
32. DISCONNECT ENGINE WIRE FROM TRANSMISSION
(a) Disconnect the PNP switch connector.
(b) Disconnect the 2 connectors from the transmission.
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P22609
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ENGINE MECHANICAL ENGINE UNIT
EM−75
1996 LAND CRUISER (RM451U)
33. REMOVE STARTER
(a) Disconnect the starter connector.
(b) Remove the 2 bolts and starter.
34. REMOVE A/T OIL COOLER PIPES FOR TRANSMIS-
SION
(a) Remove the 3 clamp mounting bolts.
(b) Loosen the 2 union nuts, and remove the oil cooler pipes.
35. DISCONNECT THROTTLE CABLE FROM THROTTLE BODY
36. REMOVE HOLE PLUG
37. REMOVE 6 TORQUE CONVERTER CLUTCH MOUNT- ING BOLT
Turn the crankshaft to gain access to each bolt. Remove the 6
bolts.
38. REMOVE TRANSMISSION FROM ENGINE
Remove the 10 bolts and transmission.
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EM1EE−02
EM−76
−
ENGINE MECHANICAL ENGINE UNIT
1996 LAND CRUISER (RM451U)
INSTALLATION
1. CHECK TORQUE CONVERTER CLUTCH INSTALLA- TION
Using calipers and straight edge, measure from the installed
surface of the torque converter clutch to the front surface of the
transmission. Correct distance: 15.7 mm (0.618 in.) or more
If the distance is less than the specifications, check for an im-
proper installation.
2. INSTALL TRANSMISSION TO ENGINE
Install the transmission with the 7 bolts. Torque: 72 N·m (730 kgf·cm, 53 ft·lbf)
3. INSTALL T ORQUE CONVERTER CLUTCH MOUNTING
BOLTS
Install the 6 bolts by turning the crankshaft. Torque: 55 N·m (550 kgf·cm, 41 ft·lbf)
HINT:
First install the green colored bolt and then the remaining 5
bolts.
4. INSTALL HOLE PLUG
5. CONNECT THROTTLE CABLE TO THROTTLE BODY
6. INSTALL A/T OIL COOLER PIPES FOR TRANSMIS-
SION
(a) Temporarily install the 3 mounting bolts.
(b) Connect the 2 oil cooler pipes to the unions on the trans-
mission. Tighten the union nuts.
Torque: 34 N·m (350 kgf·cm, 25 ft·lbf)
(c) Tighten the 3 clamp mounting bolts.
7. INSTALL STARTER
(a) Install the starter with the 2 bolts. Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)
(b) Connect the starter connector.
8. CONNECT ENGINE WIRE TO TRANSMISSION
(a) Connect the 2 connectors from the transmission.
(b) Connect the PNP switch connector.
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ENGINE MECHANICAL ENGINE UNIT
EM−77
1996 LAND CRUISER (RM451U)
9. INSTALL OIL DIPSTICK GUIDE FOR TRANSMISSION
(a) Install a new O−ring to the dipstick guide.
(b) Apply a light coat of ATF to the O −ring.
(c) Connect the dipstick guide end to the tube of the oil pan, and install the dipstick guide with the 2 bolts.
(d) Install the dipstick.
(e) Connect the 2 breather hoses.
10. INSTALL ENGINE AND TRANSMISSION ASSEMBLY IN VEHICLE
(a) Attach the engine hoist chain to the engine hangers.
(b) Lower the engine and transmission assembly into the en-
gine compartment.
(c) Insert the stud bolts of the front engine mounting insula- tors into the stud bolt holes of the frame.
(d) Temporarily install the 2 nuts holding the engine front mounting insulators to the frame crossmember.
(e) Keep the engine level with a jack.
(f) Remove the hoist chain.
11. INSTALL FRAME CROSSMEMBER
(a) Temporarily install the crossmember to the engine rear mounting insulator with the 2 nuts.
(b) Install the 8 bolts holding the crossmember to the frame. Torque: 61 N·m (620 kgf·cm, 45 ft·lbf)
(c) Tighten the 2 nuts holding the crossmember to the engine
rear mounting insulator.
Torque: 74 N·m (750 kgf·cm, 54 ft·lbf)
12. TIGHTEN NUTS HOLDING ENGINE FRONT MOUNT- ING INSULATORS TO FRAME
Torque: 74 N·m (750 kgf·cm, 54 ft·lbf)
13. CONNECT GROUND STRAP TO HEAT INSULATOR
14. INSTALL FRONT EXHAUST PIPE
(a) Install 2 new gaskets and the front exhaust pipe with the
4 nuts.
Torque: 63 N·m (630 kgf·cm, 46 ft·lbf)
(b) Install the No.1 support bracket with the 2 bolts.
Torque: 24 N·m (240 kgf·cm, 17 ft·lbf)
(c) Connect the clamp and tighten the clamp bolt. Torque: 19.5 N·m (195 kgf·cm, 14 ft·lbf)
(d) Connect the front exhaust pipe to the rear TWC with a
new gasket, 2 bolts and 2 nuts.
Torque: 46 N·m (470 kgf·cm, 34 ft·lbf)
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EM−78
−
ENGINE MECHANICAL ENGINE UNIT
1996 LAND CRUISER (RM451U)
15. INSTALL TRANSFER SHIFT LEVER
(a) Install the shift lever and hose clamp with the 4 bolts.
Torque: 18 N·m (185 kgf·cm, 13 ft·lbf)
(b) Connect the shift rod and install the pin.
(c) Install the transfer shift lever boot and transmission shift lever assembly with the 10 bolts.
Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf)
(d) Connect the 3 connectors to the transmission shift lever assembly.
(e) Install the console box with the 3 bolts.
(f) Connect the pattern select switch connector.
(g) Install the console with the 4 screws.
(h) Install the transfer shift lever knob.
(i) Shift the shift lever to N position.
(j) Fully turn the control shaft lever back and return 2 notches. It is now in neutral position.
(k) Connect the transmission control rod with the nut.
Torque: 13 N·m (130 kgf·cm, 9 ft·lbf)
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−
ENGINE MECHANICAL ENGINE UNIT
EM−79
1996 LAND CRUISER (RM451U)
16. Differential Side:
INSTALL FRONT AND REAR PROPELLER SHAFTS
(a) Align the matchmarks on the flanges and connect the
flanges with the 4 bolts and nuts.
(b) Torque the bolts and nuts. Torque:
74 N·m (750 kgf·cm, 54 ft·lbf) for front shaft
88 N·m (900 kgf·cm, 65 ft·lbf)for rear shaft
17. Transfer Side: INSTALL FRONT AND REAR PROPELLER SHAFTS
(a) Align the matchmarks on the flanges and connect the flanges with the 4 nuts.
(b) Torque the nuts. Torque:
74 N·m (750 kgf·cm, 54 ft·lbf) for front shaft
88 N·m (900 kgf·cm, 65 ft·lbf) for rear shaft
18. INSTALL STABILIZER BAR
(a) Temporarily install the stabilizer bar to the axle housing with the bolt and nut.
(b) Connect the stabilizer bar with the 2 bolts. Torque: 18 N·m (185 kgf·cm, 13 ft·lbf)
(c) Bounce the vehicle up and down to stabilize the suspen- sion.
(d) Torque the bolt and nut holding the stabilizer bar to the axle housing.
Torque: 25 N·m (260 kgf·cm, 19 ft·lbf)
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