1996 TOYOTA LAND CRUISER Hoses

AC2RU−01
Z17944
Hose ”A”
Hose ”B”
Z19353
Hose Clip
Heater
Radiator
Pipe Paint
Water Hose Upper Upper
Fr RH
Marking Hose ”A”
Hose ”B”
45°
AC−48
−
AIR CONDITIONING WATER VALVE
1375
Author: Date:
1996 LAND CRUISER (RM451U)
WATER VALVE
REMOVAL
1. DRAIN ENGINE COOLANT FROM RADIATOR
HINT:
It is not necessary to drain out all the coolant.
2. DISCONNECT WATER VALVE CONTROL CABLE
3. DISCONNECT WATER HOSES FROM HEATER RA-
DIATOR PIPE AND WATER VALVE
(a) Grip the claws of the hose clip with pliers and slide the clip
along the hose to a place where it does not clamp the
hose to the pipe.
(b) Disconnect the water hoses.
HINT:
ATt the time of installation, refer to the following procedure.
Push the water hose onto the heater radiator pipe as far
as ridge on the pipe.
Install the hose clip in a position, as shown in the illustra-
tion.
4. REMOVE WIRE HARNESS PROTECTOR
5. REMOVE WATER VALVE
Remove the 2 bolts and water valve.
N02485N18180N18181
Brought to you by BirfMark
Brought to you by BirfMark
Version 1.11 - 03/16/2010

AT0T9−01
AT−16
−
AUTOMATIC TRANSMISSION AIR COOLED OIL COOLER
1996 LAND CRUISER (RM451U)
REMOVAL
1. REMOVE RADIATOR GRILLE
(a) Remove the 5 screws.
(b) Using a screwdriver, disconnect the clip.
HINT:
Tape a screwdriver tip before use.
(c) Remove the radiator grille.
2. REMOVE OIL COOLER
(a) Loosen the 2 clips and disconnect the 2 hoses.
(b) Remove the 8 bolts and oil cooler. Torque: 11 N·m (115 kgf·cm, 8 ft·lbf)
Brought to you by BirfMark
Brought to you by BirfMark
Version 1.11 - 03/16/2010

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
Brought to you by BirfMark
Brought to you by BirfMark
Version 1.11 - 03/16/2010

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
Brought to you by BirfMark
Brought to you by BirfMark
Version 1.11 - 03/16/2010

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
Brought to you by BirfMark
Brought to you by BirfMark
Version 1.11 - 03/16/2010

EC−8
−
EMISSION CONTROL EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM
1996 LAND CRUISER (RM451U)
16. REMOVE TVV FROM CYLINDER HEAD
(a) Disconnect the 2 vacuum hoses.
(b) Remove the TVV.
17. INSPECT TVV OPERATION
(a) Cool the TVV to below 45° C (113°F) with cool water.
(b) Check that air flows from pipe J to the air filter.
(c) Heat the TVV to above 64° C (147°F) with hot water.
(d) Check that air flows from pipe J to pipe K.
If operation is not as specified, replace the TVV.
18. REINSTALL TVV
(a) Apply adhesive to 2 or 3 threads of the TVV, and install it.
Adhesive:
Part No. 08833 −00070, THREE BOND 1324
or equivalent
Torque: 29 N·m (300 kgf·cm, 22 ft·lbf)
(b) Reconnect 2 vacuum hoses.
19. REFILL WITH ENGINE COOLANT
20. REMOVE INTAKE MANIFOLD STAY
21. REMOVE VCV
Brought to you by BirfMark
Brought to you by BirfMark
Version 1.11 - 03/16/2010

EC−12
−
EMISSION CONTROL EXHAUST GAS RECIRCULATION (EGR) SYSTEM
1996 LAND CRUISER (RM451U)
HINT:
As a large amount of exhaust gas enters, the engine will misfire
slightly.
7. DISCONNECT TOYOTA HAND −HELD TESTER OR
OBD II SCAN TOOL
8. REMOVE VACUUM GAUGE
Remove the vacuum gauge, and reconnect the vacuum hoses
to the proper locations.
9. INSPECT EGR VALVE
(a) Apply vacuum directly to the EGR valve with the engine idle.
(b) Check that the engine runs rough or dies.
(c) Reconnect the vacuum hoses to the proper locations.
If no problem is found with this inspection, system is normal;
otherwise inspect each part.
10. CANCEL DIAGNOSTIC TROUBLE CODE
11. REMOVE AIR INTAKE CHAMBER (See page EM−28)
12. DISCONNECT VACUUM HOSES AND CONNECTOR
13. INSPECT VSV FOR OPEN CIRCUIT
Using an ohmmeter, check that there is continuity between the
terminals. Resistance: 30 − 34 Ω at 20° C (68°F)
If there is no continuity, replace the VSV.
14. INSPECT VSV FOR GROUND
Using an ohmmeter, check that there is no continuity between
each terminal and the body.
If there is continuity, replace the VSV.
Brought to you by BirfMark
Brought to you by BirfMark
Version 1.11 - 03/16/2010

(a)
(b)
(c)
−
EMISSION CONTROL EXHAUST GAS RECIRCULATION (EGR) SYSTEM
EC−13
1996 LAND CRUISER (RM451U)
15. INSPECT VSV OPERATION
(a) Check that the air flows from pipe G to pipe E.
(b) Apply battery voltage across the terminals.
(c) Check that the air does not flows from pipe G to pipe E.
If operation is not as specified, replace the VSV.
16. RECONNECT VACUUM HOSES AND CONNECTOR
17. REINSTALL AIR INTAKE CHAMBER (See page
EM−54 )
18. DISCONNECT V ACUUM HOSES FROM EGR V ACUUM
MODULATOR
(a) Disconnect the vacuum hose from R port.
(b) Disconnect the vacuum hose from Q port.
(c) Disconnect the vacuum hose from P port.
19. INSPECT EGR VACUUM MODULATOR OPERATION
(a) Block ports P and R with your finger.
(b) Blow air into port Q, and check that the air passes through
to the air filter side freely.
(c) Start the engine, and maintain speed at 2,500 rpm.
(d) Repeat the above test. Check that there is a strong resis-
tance to air flow.
If operation is not as specified, replace the EGR vacuum modu-
lator.
20. RECONNECT VACUUM HOSES TO EGR VACUUM
MODULATOR
(a) Connect the vacuum hose to R port.
(b) Connect the vacuum hose to Q port.
(c) Connect the vacuum hose to P port.
Brought to you by BirfMark
Brought to you by BirfMark
Version 1.11 - 03/16/2010