1996 TOYOTA LAND CRUISER elec

P09286
New O−ring
Grommet Injector
Delivery Pipe WRONG
CORRECT
P09401
Fuel Return Hose
SF−4
−
SFI SFI SYSTEM
632
Author: Date:
1996 LAND CRUISER (RM451U)
(d) Observe the following precautions when removing and
installing the injectors.
(1) Never reuse the O −ring.
(2) When placing a new O −ring on the injector, take
care not to damage it in any way.
(3) Coat a new O −ring with spindle oil or gasoline be-
fore installing −never use engine, gear or brake oil.
(e) Install the injector to the delivery pipe and intake manifold
as shown in the illustration.
(f) Check that there are no fuel leaks after doing mainte- nance anywhere on the fuel system.
(1) Remove the fuse cover on the instrument panel.
(2) Connect the TOYOTA hand− held tester to the
DLC3.
(3) Turn the ignition switch ON and TOYOTA hand −
held tester main switch ON.
NOTICE:
Do not start the engine. (4) Select the active test mode on the TOYOTA hand−held tester.
(5) Please refer to the TOYOTA hand −held tester oper-
ator ’s manual for further details.
If you have no T OYOTA hand−held tester, connect the positive
(+) and negative ( −) leads from the battery to the fuel pump con-
nector (See page SF−14 ).
(6) Pinch the fuel return hose. The pressure in the high
pressure line will rise to approx. 392 kPa (4 kgf/cm
2,
57 psi). In this state, check to see that there are no
leaks from any part of the fuel system.
NOTICE:
Always pinch the hose. Avoid bending as it may cause the
hose to crack.
(7) Turn the ignition switch to LOCK.
(8) Disconnect the TOYOTA hand −held tester from the
DLC3.
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FI4848
FI4849
SF−30
−
SFI INJECTOR
1996 LAND CRUISER (RM451U)
(f) Install the grommet and O−ring to the injector.
(g) Connect SST (union and hose) to the injector, and hold
the injector and union with SST (clamp).
SST 09268−41046
(h) Put the injector into the graduated cylinder.
HINT:
Install a suitable vinyl hose onto the injector to prevent gasoline
from splashing out.
(i) Remove the fuse cover on the instrument panel.
(j) Connect the TOYOTA hand−held tester to the DLC3.
(k) Turn the ignition switch ON and TOYOTA hand−held tes-
ter main switch ON.
NOTICE:
Do not start the engine.
(l) Select the active test mode on the TOYOTA hand −held
tester.
(m) Please refer to the TOYOTA hand −held tester operator’s
manual for further details.
(n) If you have no TOYOTA hand−held tester, connect the positive (+) and negative (−) leads from the battery to the
fuel pump connector (See page SF−14)
(o) Connect SST (wire) to the injector and battery for 15 se- conds, and measure the injection volume with a gra-
duated cylinder. Test each injector 2 or 3 times.
SST 09842−30070
Volume:
69 − 88 cm
3 (4.2 − 5.4 cu in.) per 15 seconds
Difference between each injector:
5 cm
3 (0.3 cu in.) or less
If the injection volume is not as specified, replace the injector.
2. INSPECT LEAKAGE
(a) In the condition above, disconnect the test probes of SST (wire) from the battery and check the fuel leakage from
the injector.
SST 09842−30070
Fuel drop: One drop or less per minute
(b) Turn the ignition switch to LOCK.
(c) Disconnect the negative ( −) terminal cable from the bat-
tery.
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SR16D−02
R09496
SST
SR−16
−
STEERING TILT STEERING COLUMN
1996 LAND CRUISER (RM451U)
REASSEMBLY
NOTICE:
When using a vise, do not overtighten it.
1. COAT WITH MOLYBDENUM DISULFIDE LITHIUM BASE GREASE (See page SR−9 )
2. INSTALL MAIN SHAFT ASSEMBLY
(a) Install a new bearing, bearing thrust collar and compres- sion spring to the shaft assembly.
(b) Install the shaft assembly into the column upper tube.
(c) Using SST, compress the compression spring. SST 09950−40010 (09957 −04010, 09958−04010)
NOTICE:
Do not bend the universal joint of the main shaft more than
20 °.
(d) Using snap ring pliers, install a new snap ring.
3. INSTALL TURN SIGNAL BRACKET
Torque the 2 bolts. Torque: 4.9 N·m (50 kgf·cm, 43 in.·lbf)
4. SELECT TILT NO.2 BOLTS
Select the bolt with plain thread end when the column upper
tube mark is 2, and the bolt with the hollow −tipped thread end
when the mark is 1.
NOTICE:
Select the bolt type to match each number marked in the
squares on the upper tube.
5. INSTALL COLUMN UPPER TUBE WITH MAIN SHAFT ASSEMBLY
(a) Install the collar to the shaft assembly.
(b) Install a new snap ring.
(c) Install the upper tube with the shaft assembly into the col-
umn lower tube.
(d) Using a plastic hammer, drive in the 2 tilt No.2 bolts.
6. INSTALL TILT LEVER LOCK SHAFT, TILT LEVER AS- SEMBLY, TILT SUB LEVER AND TILT LEVER
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SR3128
Mark
”A”
”A”
−
STEERING TILT STEERING COLUMN
SR−17
1996 LAND CRUISER (RM451U)
7. INSTALL 2 TILT PAWLS
(a) Coat the collar with molybdenum disulfide lithium base
grease and install it to the tilt pawl.
(b) Install the pawl.
HINT:
Install the pawl pin into the long hole of the tilt lever/ tilt sub lever.
(c) Install the bolt through the pawls and tilt lever assembly.
(d) Temporarily install the 2 washers and nut.
(e) Torque the tilt lever assembly set bolt.
Torque: 2.9 N·m (30 kgf·cm, 26 in.·lbf)
8. ENGAGE AND ADJUST 2 TILT PAWLS
(a) Engage the tilt sub lever side pawl to the center of the ratchet.
(b) While turning the tilt lever side tilt pawl collar, completely engage the tilt lever side pawl to the ratchet.
(c) Torque the nut.
Torque: 5.9 N·m (60 kgf·cm, 52 in.·lbf)
9. SELECT AND INSTALL 2 TILT PAWL STOPPERS
(a) With the tilt pawl and ratchet engaged, install the stopper.
(b) Check that the alignment marks on the stopper and pawl
align when the stopper is rotated to the pawl side.
(c) If the alignment marks do not align, select stopper accord-
ing to the following table.
Tilt lever sideTilt sub lever sideDimension ”A”
mm (in.)
1A12.65 − 12.75
(0.4980 − 0.5020)
2B12.55 − 12.65
(0.4941 − 0.4980)
3C12.45 − 12.55
(0.4902 − 0.4941)
4D12.35 − 12.45
(0.4862 − 0.4902)
5E12.25 − 12.35
(0.4823 − 0.4862)
(d) After selecting the stoppers, check that on both sides the
pawl and ratchet are fully engaged.
10. INSTALL 2 TILT LEVER RETAINERS
(a) Install a new E−ring.
(b) Torque the nut. Torque: 15 N·m (150 kgf·cm, 11 ft·lbf)
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SS1EY−03
−
SERVICE SPECIFICATIONS IGNITION
SS−17
140
Author: Date:
1996 LAND CRUISER (RM451U)
IGNITION
SERVICE DATA
Firing order−1 − 5 − 3 − 6 − 2 − 4
High −tension cordResistance Maximum25 kΩ per cord
Spark plugRecommended spark plug ND
NGK
Correct electrode gapK16R−U
BKR5EYA
0.8 mm (0.031 in.)
Ignition coilPrimary coil resistance at cold
at hot
Secondary coil resistance at cold
at hot0.36 − 0.55 Ω
0.45 − 0.65 Ω
9.0 − 15.4 kΩ
11.4 − 18.1 kΩ
DistributorAir gap
Pickup coil resistance at cold (G1 − G)
(G2 − G)
(NE − G)
at hot (G1 − G )
(G2 − G)
(NE − G)0.2 − 0.4 mm (0.008 − 0.016 in.)
185 − 275 Ω
185 − 275 Ω
185 − 275 Ω
240 − 325 Ω
240 − 325 Ω
240 − 325 Ω
Crankshaft
position sensorResistance at cold (NE − NE )
at hot (NE − NE )1,630 − 2,740 Ω
2,065 − 3,225 Ω
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SS1EJ−02
SS−40
−
SERVICE SPECIFICATIONS BODY ELECTRICAL
163
Author: Date:
1996 LAND CRUISER (RM451U)
BODY ELECTRICAL
SERVICE DATA
TURN SIGNAL FLASHER
Flashes/Minute60 − 120
SPEEDOMETER (USING A SPEEDOMETER)
Standard indication (mph)Allowable range (mph)
2018 − 24
4038 − 44
6058 − 66
8078 − 88
10098 − 11 0
12011 8 − 132
TACHOMETER (ON− VEHICLE) DC 13.5 V 25°C (77° F)
Standard indication (RPM)Allowable range (RPM)
700630 − 770
1,000900 − 1,100
2,0001,875 − 2,125
3,0002,850 − 3,150
4,0003,850 − 4,150
5,0004,850 − 5,150
FUEL RECEIVER GAUGE
A − B85.5 − 105.5 Ω
A − C126 − 150 Ω
B − C90 − 110 Ω
FUEL SENDER GAUGE
Float position F: Approx. 15 mm ((0.59 in.)Approx. 3 Ω
Float position E: Approx. 200 (7.87 in.)Approx. 110 Ω
ENGINE COOLANT TEMPERATURE RECEIVER GAUGE
A − B71 − 79 Ω
A − C117 − 141 Ω
B − C185 − 215 Ω
OIL PRESSURE RECEIVER GAUGE
Resistance40 − 48 Ω
CRUISE CONTROL SWITCH
Switch position OFFNo continuity
Switch position RESUME/ACCELApprox. 68 Ω
Switch position SET/COASTApprox. 198 Ω
Switch position CANCELApprox. 418 Ω
CRUISE CONTROL ACTUATOR
1 − 3Approx. 2 kΩ
2 − 3Approx. 0.5 − 1.7 kΩ
Actuator control arm free play0 mm (0 in.)
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Z18976
B
Z18977
C
TR−6
−
TRANSFER TRANSFER ASSEMBLY
1996 LAND CRUISER (RM451U)
11. REMOVE RETAINER FROM REAR CASE
Remove the 5 bolts and retainer.
Torque: 39 N·m (400 kgf·cm, 28 ft·lbf)
12. REMOVE ADJUSTING SHIM
HINT:
At the time of assembly, select adjusting shims for the idler gear
rear taper roller bearing.
(a) Using vernier calipers, measure dimension A.
(b) Lightly hold down the bearing outer race in the thrust direction to eliminate any looseness before making the
measurement.
(c) Using a steel straight edge and feeler gauge, measure the clearance of dimension B.
(d) Calculate the required thickness of the adjusting shim. Thickness:
Dimension A + Dimension B + (0.022 − 0.049 mm,
0.0009 − 0.0019 in.)
(e) From the following table, select a shim so that its thick- ness is within the range of the calculation.
MarkThickness mm (in.)MarkThickness mm (in.)
20.30 (0.0118)83.20 (0.1260)
30.45 (0.0177)93.40 (0.1339)
42.40 (0.0945)103.60 (0.1417)
52.60 (0.1024)113.80 (0.1496)
62.80 (0.1 102)124.00 (0.1575)
73.00 (0.1181)130.55 (0.0216)
HINT:
At the time of reassembly, select adjusting shims for the output
shaft taper roller bearing.
(f) Using a steel straight edge and feeler gauge, measure
the clearance of dimension C.
(g) Lightly hold down the bearing outer race in the thrust direction to eliminate any looseness before making the
measurement.
(h) Calculate the required thickness of the adjusting shim.
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Q07126
FIPG
Q08404
FIPG
A
−
TRANSFER TRANSFER ASSEMBLY
TR−7
1996 LAND CRUISER (RM451U)
Thickness:
Dimension C + (0. 014 − 0.039 mm, 0.0006 − 0.0015 in.)
(i) From the following table, select a shim so that its thick-
ness is within the range of the calculation.
MarkThickness mm (in.)MarkThickness mm (in.)
B0.30 (0.0118)H1.80 (0.0709)
C0.45 (0.0177)J2.00 (0.0787)
D1.00 (0.0394)K2.20 (0.0866)
E1.20 (0.0472)L2.40 (0.0945)
F1.40 (0.0551)M2.60 (0.1024)
G1.60 (0.0630)N0.55 (0.0216)
13. REMOVE OIL STRAINER FROM REAR CASE
Remove the 2 set bolts and oil strainer.Torque: 4.9 N·m (50 kgf·cm, 43 in.·lbf)
14. REMOVE CASE COVER
(a) Remove the 5 bolts.
HINT:
At the time of reassembly, apply liquid sealer to the bolt threads.
Sealant: Part No.08833−00080, THREE BOND 1344,
LOCTITE 242 or equivalent
Torque: 37 N·m (380 kgf·cm, 27 ft·lbf)
(b) Using a brass bar and hammer, tap the case cover and remove it.
HINT:
At the time of reassembly, apply FIPG to the rear case. FIPG: Part No. 08826−00090, THREE BOND 1281 or
equivalent
15. SEPARATE FRONT CASE AND REAR CASE
(a) Using a snap ring expander, remove the snap ring from the rear case.
(b) Remove the 8 bolts.
HINT:
At the time of reassembly, apply liquid sealer to the ”A” bolt
threads. Sealant: Part No.08833 −00080, THREE BOND 1344,
LOCTITE 242 or equivalent
Torque:37 N·m (380 kgf·cm, 27 ft·lbf)
(c) Using a brass bar and hammer, tap the rear case and sep-
arate it.
HINT:
At the time of reassembly, apply FIPG to the front case.
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