1996 TOYOTA LAND CRUISER Workshop Manual

−
INTRODUCTION FOR ALL OF VEHICLES
IN−15
15
Author: Date:
1996 LAND CRUISER (RM451U)
3. FOR VEHICLES EQUIPPED WITH A CATALYTIC CONVERTER
CAUTION:
If large amount of unburned gasoline flows into the converter, it may overheat and create a fire haz-
ard. To prevent this, observe the following precautions and explain them to yo\
ur customer.
(a) Use only unleaded gasoline.
(b) Avoid prolonged idling.
Avoid running the engine at idle speed for more than 20 minutes.
(c) Avoid spark jump test. (1) Perform spark jump test only when absolutely necessary. Perform this test as rapidly as possible.
(2) While testing, never race the engine.
(d) Avoid prolonged engine compression measurement. Engine compression tests must be done as rapidly as possible.
(e) Do not run engine when fuel tank is nearly empty. This may cause the engine to misfire and create an extra load on the con\
verter.
(f) Avoid coasting with ignition turned off.
(g) Do not dispose of used catalyst along with parts contaminated with gasol\
ine or oil.
4. IF VEHICLE IS EQUIPPED WITH MOBILE COMMUNICATION SYSTEM
For vehicles with mobile communication systems such as two− way radios and cellular telephones, observe
the following precautions. (1) Install the antenna as far as possible away from the ECU and sensors of the vehicle’\
s electronic
system.
(2) Install the antenna feeder at least 20 cm (7.87 in.) away from the ECU and se\
nsors of the ve- hicle’s electronic systems. For details about ECU and sensors locations, refer\
to the section on
the applicable component.
(3) Avoid winding the antenna feeder together with other wiring as much as possible, and also avoid
running the antenna feeder parallel with other wire harnesses.
(4) Check that the antenna and feeder are correctly adjusted.
(5) Do not install powerful mobile communications system.
5. FOR USING OBD II SCAN TOOL OR TOYOTA HAND −HELD TESTER
CAUTION:
Observe the following items for safety reasons:
Before using the OBD II scan tool or TOYOTA hand −held tester, the OBD II scan tool’s instruc-
tion book or TOYOTA hand −held tester’s operator manual should be read thoroughly.
Be sure to route all cables securely when driving with the OBD II scan too\
l or TOYOTA hand −
held tester connected to the vehicle. (i.e. Keep cables away from feet,\
pedals, steering wheel
and shift lever.)
Two persons are required when test driving with the OBD II scan tool or TOYOTA hand −held
tester, one person to drive the vehicle and the other person to operate the OBD\
II scan tool or
TOYOTA hand−held tester.
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BE2826
Cassette Tape Slot Cover
IN−16
−
INTRODUCTION FOR ALL OF VEHICLES
16
Author: Date:
1996 LAND CRUISER (RM451U)
6. FOR VEHICLES WITH AN AUDIO SYSTEM WITH
BUILT−IN ANTI−THEFT SYSTEM
Audio System displaying the sign ANTI −THEFT SYSTEM
shown on the left has a built −in anti −theft system which makes
the audio system soundless if stolen.
If the power source for the audio system is cut even once, the
anti0theft system operates so that even if the power source is
reconnected, the audio system will not produce any sound un-
less the ID number selected by the customer is input again. Ac-
cordingly, when performing repairs on vehicles equipped with
this system, before disconnecting the battery terminals or re-
moving the audio system the customer should be asked for the
ID number afterwards, or else a request made to the customer
to input the ID number. For the method to input the ID number
or cancel the anti−theft system, refer to the Owner’s Manual.
ANTI-THEFTSYSTEM
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IN04S−30
−
INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMSIN−17
17
Author: Date:
1996 LAND CRUISER (RM451U)
HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS
GENERAL INFORMATION
A large number of ECU controlled systems are used in the LAND CRUISER. In general, the ECU controlled
system is considered to be a very intricate system requiring a high level of t\
echnical knowledge and expert
skill to troubleshoot. However, the fact is that if you proceed to inspect the circuits one by one, trou\
bleshoot-
ing of these systems is not complex. If you have adequate understanding of the system and a basic knowl-
edge of electricity, accurate diagnosis and necessary repair can be performed to locate and fix the pr\
oblem.
This manual is designed through emphasis of the above standpoint to help service techn\
icians perform ac-
curate and effective troubleshooting, and is compiled for the following major ECU con\
trolled systems:
The troubleshooting procedure and how to make use of it are described on\
the following pages.
SystemPage
1. EngineDI−1
2. Automatic TransmissionDI−129
3. Anti− Lock Brake SystemDI−188
4. Supplemental Restraint SystemDI−238
5. Cruise Control SystemDI−284
FOR USING OBD II SCAN TOOL OR TOYOTA HAND−HELD TESTER
Before using the scan tool or tester, the scan tool’ s instruction book or tester’s operator manual should
be read thoroughly.
If the scan tool or tester cannot communicate with ECU controlled systems \
when you have connected
the cable of the scan tool or tester to DLC3, turned the ignition switch\
ON and operated the scan tool,
there is a problem on the vehicle side or tool side.
(1) If communication is normal when the tool is connected to another vehicle, \
inspect the diagnosis data link line (Bus line) or ECU power circuit of the vehicle.
(2) If communication is still not possible when the tool is connected to anoth\
er vehicle, the problem is probably in the tool itself, so perform the Self Test procedures outline in the Tester Operator’s
Manual.
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IN04T−19
Vehicle Brought to Workshop
Customer Problem
Analysis
Symptom Confirmation
and Diagnostic Trouble
Code Check
Symptom Simulation
Diagnostic Trouble
Code Chart
Problem Symptoms Table
Circuit Inspection or Parts
Inspection
Repair
Confirmation Test
End
1
2
4 3
5
6 78 Ask the customer about the conditions and the
environment when the problem occurred.
1
Confirm the symptoms and the problem conditions,
and check the diagnostic trouble codes.
(When the problem symptoms do not appear
during confirmation, use the symptom simulation
method described later on.) 2, 3
Check the results obtained in Step 2, then confirm
the inspection procedure for the system or the part
which should be checked using the diagnostic
trouble code chart or the problem symptoms table. 4, 5, 6
Check and repair the affected system or part in
accordance with the instructions in Step 6. 7
After completing repairs, confirm that the problem
has been eliminated.
(If the problem is not reproduced, perform the
confirmation test under the same conditions and
in the same environment as when it occurred for
the first time.) 8
IN−18−
INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMS
1996 LAND CRUISER (RM451U)
HOW TO PROCEED WITH TROUBLESHOOTING
Carry out troubleshooting in accordance with the procedure on the following page. Here, only the basic pro-
cedure is shown. Details are provided in Diagnostics section, showing the most\
effective methods for each
circuit. Confirm the troubleshooting procedures first for the relevant circuit before beg\
inning troubleshooting
of that circuit.
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Important Points in the Customer Problem Analysis
 What −−−−− Vehicle model, system name
 When −−−−− Date, time, occurrence frequency
 Where −−−−− Road conditions
 Under what conditions? −−−−− Running conditions, driving conditions, weather conditions
 How did it happen? −−−−− Problem symptoms
(Sample) Engine control system check sheet.
ENGINE CONTROL SYSTEM Check Sheet
Customer’s Name
Driver’s Name
Data Vehicle
Brought in
License No.
Model and Model
Year
Frame No.
Engine Model
Odometer Reading
km
miles
Problem Symptoms
Engine does
not Start
Difficult to
Start
Poor Idling
Poor
Drive ability
Engine Stall
Others
Engine does not crankNo initial combustionNo complete combustion
Engine cranks slowly
Other
Incorrect first idleIdling rpm is abnormalHigh ( rpm)Low ( rpm)
Rough idling
Other
HesitationBack fireMuffler explosion (after− fire)Surging
Knocking
Other
Soon after startingAfter accelerator pedal depressed
After accelerator pedal released
During A/C operation
Shifting from N to D
Other
Data Problem
ConstantSometimes ( times per day/month)
Inspector’s
Name
CUSTOMER PROBLEM ANALYSIS CHECK
−
INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMSIN−19
1996 LAND CRUISER (RM451U)
1. CUSTOMER PROBLEM ANALYSIS
In troubleshooting, the problem symptoms must be confirmed accurately an\
d all preconceptions must be
cleared away in order to give an accurate judgment. To ascertain just what the problem symptoms are, it is
extremely important to ask the customer about the problem and the conditions at t\
he time it occurred.
Important Point in the Problem Analysis:
The following 5 items are important points in the problem analysis. Past pr\
oblems which are thought to be
unrelated and the repair history, etc. may also help in some cases, so as much information as possible s\
hould
be gathered and its relationship with the problem symptoms should be corre\
ctly ascertained for reference
in troubleshooting. A customer problem analysis table is provided in Diagnostics section for each system
for your use.
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DIAGNOSTIC TROUBLE CODE CHECK PROCEDURE
Diagnostic Trouble
Code Check (Make a
note of and then clear) Confirmation
of Symptoms
Diagnostic Trouble
Code Check
Problem Condition
Diagnostic Trouble
Code Display Problem symptoms
exist
Same diagnostic
trouble code is
displayed Problem is
still occurring in the diagnostic
circuit
Normal code is
displayed The problem is still occurring in a place
other than in the diagnostic circuit
(The diagnostic trouble code displayed
first is either for a past problem or it is a
secondary problem)
No problem
symptoms exist
The problem occurred in the diagnostic
circuit in the past
Normal Code Display Problem symptoms
existNormal code is
displayed The problem is still occurring in a place
other than in the diagnostic circuit
No problem
symptoms exist
Normal code is
displayed The problem occurred in a place other
than in the diagnostic circuit in the past
IN−20−
INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMS
1996 LAND CRUISER (RM451U)
2. SYMPTOM CONFIRMATION AND DIAGNOSTIC TROUBLE CODE CHECK
The diagnostic system in the LAND CRUISER fulfills various functions. The first functio\
n is the Diagnostic
Trouble Code Check in which a malfunction in the signal circuits to the ECU is stored in co\
de in the ECU
memory at the time of occurrence, to be output by the technician during troubl\
eshooting. Another function
is the Input Signal Check which checks if the signals from various switc\
hes are sent to the ECU correctly.
By using these check functions, the problem areas can be narrowed down qui\
ckly and troubleshooting can
be performed ef fectively. Diagnostic functions are incorporated in the following systems in the LAND CRUIS-
ER.
SystemDiagnostic Trouble
Code CheckInput Signal Check(Sensor Check)Diagnostic Test
Mode (Active Test)
1. Engine
(with Check Mode)
2. Automatic T ransmission
(with Check Mode)
3. Anti− Lock Brake System
4. Supplemental Restraint System
5. Cruise Control System
In diagnostic trouble code check, it is very important to determine whethe\
r the problem indicated by the diag-
nostic trouble code is still occurring or occurred in the past but returned to\
normal at present. In addition,
it must be checked in the problem symptom check whether the malfunction \
indicated by the diagnostic
trouble code is directly related to the problem symptom or not. For this reason, the \
diagnostic trouble codes
should be checked before and after the symptom confirmation to determine the curre\
nt conditions, as shown
in the table below. If this is not done, it may, depending on the case, result in unnecessary troubleshooting
for normally operating systems, thus making it more difficult to locate the problem, or in repairs not pertinent
to the problem. Therefore, always follow the procedure in correct order an\
d perform the diagnostic trouble
code check.
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Diagnostic trouble code check
Making a note of and clearing of the diagnostic trouble codes displayed Symptom confirmation No problem symptoms
exist
Problem symptoms
exist
Simulation test using the symptom
simulation methods
 Normal code displayed
 Problem symptoms exist  Normal code displayed
 No problem symptoms exist
Diagnostic trouble code check
Troubleshooting of problem indicated
by diagnostic trouble code  Diagnostic trouble code displayed
 Problem symptoms exist
System Normal
Troubleshooting of each
problem symptom
If a diagnostic trouble code was
displayed in the initial diagnostic
trouble code check, it indicates
that the trouble may have occurred
in a wire harness or connector in
that circuit in the past. Therefore,
check the wire harness and con-
nectors (See page IN−28).
−
INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMSIN−21
1996 LAND CRUISER (RM451U)
Taking into account the points on the previous page, a flow chart showing how to proceed with troubleshoot-
ing using the diagnostic trouble code check is shown below. This flow chart shows how to utilize the diagnos-
tic trouble code check effectively, then by carefully checking the results, indicates how to proceed eithe\
r to
diagnostic trouble code troubleshooting or to troubleshooting of problem symptoms \
table.
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V07268
VIBRATION METHOD: When vibration seems to be the major cause.
CONNECTORS
WIRE HARNESS
PARTS AND SENSOR 1
Slightly shake the connector vertically and horizontally.
Slightly shake the wire harness vertically and horizontally.
The connector joint, fulcrum of the vibration, and body
through portion are the major areas to be checked thorough-
ly.
Apply slight vibration with a finger to the part of the sensor
considered to be the pr oblem cause and check that the mal-
function occurs. Shake Slightly
Swing SlightlyVibrate Slightly
HINT:
Applying strong vibration to relays may result in open relays.
IN−22
−
INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMS
1996 LAND CRUISER (RM451U)
3. SYMPTOM SIMULATION
The most dif ficult case in troubleshooting is when there are no problem symptoms occurring. In such\
cases,
a thorough customer problem analysis must be carried out, then simulate \
the same or similar conditions and
environment in which the problem occurred in the customer’s vehicle. No matter how much experience a
technician has, or how skilled he may be, if he proceeds to troubleshoot without c\
onfirming the problem
symptoms he will tend to overlook something important in the repair operation an\
d make a wrong guess
somewhere, which will only lead to a standstill. For example, for a problem which only occurs \
when the en-
gine is cold, or for a problem which occurs due to vibration caused by the road during\
driving, etc., the prob-
lem can never be determined so long as the symptoms are confirmed with t\
he engine hot condition or the
vehicle at a standstill. Since vibration, heat or water penetration (moisture) is l\
ikely cause for problem which
is difficult to reproduce, the symptom simulation tests introduced here are ef\
fective measures in that the ex-
ternal causes are applied to the vehicle in a stopped condition.
Important Points in the Symptom Simulation Test:
In the symptom simulation test, the problem symptoms should of course be c\
onfirmed, but the problem area
or parts must also be found out. To do this, narrow down the possible problem circuits according to the symp-
toms before starting this test and connect a tester beforehand. After that, \
carry out the symptom simulation
test, judging whether the circuit being tested is defective or normal and also confirming the \
problem symp-
toms at the same time. Refer to the problem symptoms table for each syst\
em to narrow down the possible
causes of the symptom.
FI2331
FI2332
FI2330
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