1996 TOYOTA LAND CRUISER Cruise control

EC0GC−01
EC−10
−
EMISSION CONTROL EXHAUST GAS RECIRCULATION (EGR) SYSTEM
623
Author: Date:
1996 LAND CRUISER (RM451U)
EXHAUST GAS RECIRCULATION (EGR) SYSTEM
COMPONENTS
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EC0JT−01
−
EMISSION CONTROL EXHAUST GAS RECIRCULATION (EGR) SYSTEM
EC−11
1996 LAND CRUISER (RM451U)
INSPECTION
1. INSPECT AND CLEAN FILTER IN EGR V ACUUM MOD-
ULATOR
(a) Remove the cap and filter.
(b) Check the filter for contamination or damage.
(c) Using compressed air, clean the filter.
(d) Reinstall the filter and cap.
HINT:
Install the filter with the coarser surface facing the atmospheric
side (outward).
2. INSTALL VACUUM GAUGE
Using a 3 −way connector, connect a vacuum gauge to the hose
between the EGR valve and EGR vacuum modulator.
3. INSPECT SEATING OF EGR VALVE
Start the engine and check that the engine starts and runs at
idle.
4. CONNECT TOYOTA HAND− HELD TESTER OR OBD II
SCAN TOOL (See page EM−10)
5. INSPECT VSV OPERATION WITH COLD ENGINE
(a) The engine coolant temperature should be below 47 °C
(117 °F).
(b) Check that the vacuum gauge indicates zero at 2,500 rpm.
(c) Check that the EGR pipe is not hot.
6. INSPECT OPERATION OF VSV AND EGR VACUUM
MODULATOR WITH HOT ENGINE
(a) Warm up the engine to above 53° C (127°F).
(b) Check that the vacuum gauge indicates low vacuum at 2,500 rpm.
(c) Disconnect the vacuum hose port R of the EGR vacuum modulator and connect port R directly to the air intake
chamber with another hose.
(d) Check that the vacuum gauge indicates high vacuum at 2,500 rpm.
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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.
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(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.
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EC−14
−
EMISSION CONTROL EXHAUST GAS RECIRCULATION (EGR) SYSTEM
1996 LAND CRUISER (RM451U)
21. REMOVE EGR VACUUM MODULATOR
22. REMOVE EGR VALVE
(a) Disconnect the vacuum hose from the EGR valve.
(b) Disconnect the engine wire from the clamp.
(c) Loosen the EGR pipe union nut.
(d) Remove the 2 nuts holding the EGR valve to the air intake
chamber.
(e) Using 2 nuts, remove the 2 stud bolts, EGR valve and gasket.
23. INSPECT EGR VALVE
Check for sticking and heavy carbon deposits.
If a problem is found, replace the valve.
24. REINSTALL EGR VALVE
(a) Using 2 nuts, temporarily install a new gasket, and EGR valve with the 2 stud bolts.
Torque: 9 N·m (90 kgf·cm, 78 in.·lbf)
(b) Install the 2 nuts holding the EGR valve to the air intake
chamber.
Torque: 18 N·m (180 kgf·cm, 13 ft·lbf)
(c) Tighten the union nut of the EGR pipe. Torque: 64 N·m (650 kgf·cm, 47 ft·lbf)
(d) Connect the engine wire to the clamp.
(e) Connect the vacuum hose to the EGR valve.
25. REINSTALL EGR VACUUM MODULATOR
Torque: 18 N·m (185 kgf·cm, 13 ft·lbf)
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EC0H3−02
−
EMISSION CONTROL THREE−WAY CATALYTIC CONVERTER (TWC)
SYSTEMEC−15
628
Author: Date:
1996 LAND CRUISER (RM451U)
THREE−WAY CATALYTIC CONVERTER (TWC) SYSTEM
INSPECTION
1. EXHAUST PIPE ASSEMBLY INSPECTION
(a) Check connection for looseness or damage
(b) Check clamps for weakness, cracks or damage
2. TWC INSPECTION
Check for dents or damage
If any part of the protector is damaged or dented to the extent that it touches the TWC, repair or replace it.
3. HEAT INSULATOR INSPECTION
(a) Check heat insulator for damage
(b) Check for adequate clearance between TWC and heat insulator.
4. FRONT TWC AND REAR TWC REPLACEMENT (See page EM−11 0 )
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EM1E3−01
EM−28
−
ENGINE MECHANICAL CYLINDER HEAD
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 AIR CLEANER HOSE AND CAP
4. DISCONNECT CRUISE CONTROL ACTUATOR CABLE FROM THROTTLE BODY
5. DISCONNECT ACCELERATOR CABLE FROM
THROTTLE BODY
6. DISCONNECT THROTTLE CABLE FROM THROTTLE BODY
7. DISCONNECT ENGINE GROUND STRAPS
(a) Disconnect the ground strap from the No. 1 engine hang-
er.
(b) Disconnect the ground strap from the air intake chamber.
8. DISCONNECT CONNECTOR ON INTAKE MANIFOLD FROM LH FENDER APRON
9. DISCONNECT BRAKE BOOSTER VACUUM HOSE
10. DISCONNECT EVAP HOSE
11. DISCONNECT FUEL RETURN HOSE
12. DISCONNECT HEATER HOSES
13. DISCONNECT ENGINE WIRE AND HEATER VALVE FROM COWL PANEL
(a) Remove the 2 bolts and disconnect the engine wire and
ground strap.
(b) Remove the 2 bolts and disconnect the heater valve.
14. REMOVE NO. 2 AND NO. 3 CYLINDER HEAD COVERS
Remove the 4 bolts and head covers.
15. REMOVE DISTRIBUTOR (See page IG−10 )
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EM−30
−
ENGINE MECHANICAL CYLINDER HEAD
1996 LAND CRUISER (RM451U)
(b) Disconnect the connectors.
(1) Disconnect the knock sensor connector.
(2) Disconnect the oil level sensor connector.
(3) Disconnect the 2 connectors from the transmission.
(4) Disconnect the starter connector.
(c) Disconnect the 2 heated oxygen sensor connectors.
(d) Disconnect the PNP switch connector.
(e) Remove the 2 bolts and disconnect the engine wire from the intake manifold and cylinder block.
(f) Disconnect the PCV hose from the PCV valve.
(g) Remove the bolt holding the engine wire to the intake manifold.
(h) Disconnect the connectors. (1) Disconnect the connector for the emission controlvalve set assembly.
(2) Disconnect the 3 injector connectors.
(i) Disconnect the engine wire clamp.
(j) Disconnect the engine wire clamp.
(k) Disconnect the connectors.
(1) Disconnect the 3 injector connectors.
(2) Disconnect the EGR gas temp. sensor connector.
(l) Disconnect the clamp of the No. 6 injector wire from the bracket.
(m) Disconnect the engine wire from the cylinder head and in-
take manifold.
25. DISCONNECT NO. 2 WATER BYPASS PIPE
Remove the 3 bolts, and disconnect the bypass pipe from the
cylinder head.
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