1996 TOYOTA LAND CRUISER generator

P08244
SST (A)
SST (C)
Turn
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CHARGING GENERATOR
CH−17
1996 LAND CRUISER (RM451U)
(f) To torque the pulley nut turn SST (A) in the direction
shown in the illustration.
Torque: 110.5 N·m (1,128 kgf·cm, 81 ft·lbf)
(g) Remove the generator from SST (C).
(h) Turn SST (B), and remove SST (A and B).
5. INSTALL RECTIFIER HOLDER
(a) Place the seal plate on the rectifier end frame.
(b) Install the 4 rubber insulators on the lead wires.
(c) Install the rectifier holder with the 4 screws. Torque: 2.9 N·m (30 kgf·cm, 25 in.·lbf)
6. INSTALL VOLTAGE REGULATOR
Install the voltage regulator on the rectifier end frame with the
3 screws. Torque: 2.0 N·m (20 kgf·cm, 17 in.·lbf)
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CH−18
−
CHARGING GENERATOR
1996 LAND CRUISER (RM451U)
7. INSTALL BRUSH HOLDER
(a) Install the brush holder on the rectifier end frame with the
2 screws.
NOTICE:
Be careful of the holder installation direction. Torque: 2.0 N·m (20 kgf·cm, 17 in.·lbf)
(b) Place the brush holder cover on the brush holder.
8. INSTALL REAR END COVER
(a) Install the end cover together with the rectifier plate. (1) Hand tighten the bolt first for positioning the plate.
(2) Tighten the 3 nuts and bolt.
Torque:
Bolt: 3.8 N·m (39 kgf·cm, 34 in.·lbf)
Nut: 4.4 N·m (45 kgf·cm, 39 in.·lbf)
(b) Install the terminal insulator with the nut. Torque: 4.1 N·m (42 kgf·cm, 36 in.·lbf)
9. CHECK THAT ROTOR ROTATES SMOOTHLY
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CH06N−03
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CHARGING GENERATOR
CH−19
1996 LAND CRUISER (RM451U)
INSTALLATION
1. INSTALL GENERATOR
(a) Mount generator on the generator bracket with the pivot
bolt. Do not tighten the bolt yet.
(b) Install the drive belt adjusting bar with the bolt and nut. Torque: 21 N·m (210 kgf·cm, 15 ft·lbf)
(c) Temporarily install the lock bolt.
(d) Connect the generator connector.
(e) Connect the generator wire with the nut and rubber cap.
(f) Connect the generator wire clamp to the generator.
2. INSTALL DRIVE BELTS
(a) Install the drive belts.
(b) Adjust the drive belt with the adjusting bolt (See page
CH−2 ).
(c) Tighten the pivot and adjusting lock bolts. Torque:
Pivot bolt: 59 N·m (600 kgf·cm, 43 ft·lbf)
Lock bolt: 21 N·m (210 kgf·cm, 15 ft·lbf)
3. CONNECT POWER STEERING (PS) RESERVOIR TANK
4. INSTALL BATTERY TRAY AND BATTERY
5. PERFORM ON−VEHICLE INSPECTION (See page CH−2 )
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R13679
BatteryFL BLOCK 2
MAIN
W
W
ECU−B
1
F/B
S7
B−R
2
3
SRS Warning
Light
8LA
Tc
B−Y8
IH1 Airbag Sensor
Assembly
DLC1
5 W−L
11
GENERATOR
(ALTERNATOR)
W
Cruise Control ECU
W−L
W−L
B−Y
B−Y
IH1 S7 S6
S6
Short Connector
Short Connector W−L
B−L
11
12
3
EA3 11
22
7
DI−274
−
DIAGNOSTICS SUPPLEMENTAL RESTRAINT SYSTEM
1996 LAND CRUISER (RM451U)
SRS Warning Light System Malfunction (Always lit up, when igni-
tion switch is in LOCK position.)
CIRCUIT DESCRIPTION
The SRS warning light is located on the combination meter.
When the SRS is normal, the SRS warning light lights up for approx. 6 seconds after the \
ignition switch is
turned from LOCK position to ACC or ON position, and then turns off automatically.
If there is a malfunction in the SRS, the SRS warning light lights up to\
inform the driver of the abnormality.
When terminals Tc and E1 of the DLC1 are connected, the DTC is displayed by the blinking\
of the SRS warn-
ing light.
WIRING DIAGRAM
DI5QD−03
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−
ENGINE MECHANICAL CYLINDER HEAD
EM−29
1996 LAND CRUISER (RM451U)
16. DISCONNECT PS RESERVOIR TANK
Remove the 3 bolts and disconnect the reservoir tank.
17. DISCONNECT RADIATOR INLET HOSE
18. DISCONNECT NO. 3 WATER BYPASS HOSE
19. REMOVE GENERATOR (See page CH−8 )
20. REMOVE THROTTLE BODY (See page SF−45)
21. REMOVE OIL DIPSTICKS AND GUIDES FOR ENGINE AND TRANSMISSION
(a) Remove the 2 mounting bolts.
(b) Pull out the dipstick together with dipstick guide.
(c) Remove the O−ring from the dipstick guide.
22. REMOVE INTAKE MANIFOLD STAY
Remove the 2 bolts and intake manifold stay.
23. DISCONNECT FUEL INLET HOSE
Remove the union bolt and 2 gaskets, and disconnect the fuel
inlet hose from the fuel filter.
24. DISCONNECT ENGINE WIRE
(a) Disconnect the connectors. (1) Disconnect the ECT sender gauge connector.
(2) Disconnect the ECT cut switch connector.
(3) Disconnect the ECT sensor connector.
(4) Disconnect the knock sensor connector.
(5) Disconnect the crankshaft position sensor connec-tor.
(6) Remove the bolt and disconnect the engine wire from the cylinder block.
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EM1E4−01
−
ENGINE MECHANICAL CYLINDER HEAD
EM−37
1996 LAND CRUISER (RM451U)
DISASSEMBLY
1. REMOVE GENERATOR BRACKET
Remove the 2 bolts and generator bracket.
2. REMOVE WATER OUTLET
Remove the 2 nuts, water outlet and gasket.
3. REMOVE EGR PIPE
(a) Loosen the union nut.
(b) Remove the 2 bolts, EGR pipe and gasket.
4. REMOVE HEATER INLET PIPE AND HOSE
Remove the 2 bolts, and disconnect the pipe and hose.
5. REMOVE AIR INTAKE CHAMBER AND INTAKE MAN-
IFOLD ASSEMBLY
(a) Disconnect the 2 vacuum hoses from the TVV.
(b) Remove the 10 bolts, 2 nuts, intake manifold and gasket.
6. DISASSEMBLE AIR INTAKE CHAMBER AND INTAKE MANIFOLD ASSEMBLY
(a) Disconnect the vacuum sensing hose from the fuel pres-
sure regulator.
(b) Remove the 6 bolts, 2 nuts, air intake chamber and 2 gas-
kets from the intake manifold.
7. REMOVE NO. 1 WATER BYPASS HOSE
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−
ENGINE MECHANICAL CYLINDER HEAD
EM−53
1996 LAND CRUISER (RM451U)
(d) Using a plastic−faced hammer, lightly tap the valve stem
tip to ensure a proper fit.
7. INSTALL VALVE LIFTERS AND SHIMS
(a) Install the valve lifter and shim.
(b) Check that the valve lifter rotates smoothly by hand.
8. INSTALL ACCELERATOR CABLE BRACKET AND THROTTLE CABLE BRACKET
9. INSTALL 2 ENGINE WIRE CLAMP BRACKETS
10. INSTALL NO. 1 AND NO. 2 ENGINE HANGERS Torque: 41 N·m (420 kgf·cm, 30 ft·lbf)
11. INSTALL NO. 1 WATER BYPASS HOSE
12. ASSEMBLE AIR INTAKE CHAMBER AND INTAKE MANIFOLD ASSEMBLY
(a) Install 2 new gaskets and the air intake chamber with the
6 bolts and 2 nuts.
Torque: 21 N·m (210 kgf·cm, 15 ft·lbf)
(b) Connect the vacuum sensing hose to the fuel pressure regulator.
13. INSTALL AIR INTAKE CHAMBER AND INTAKE MAN- IFOLD ASSEMBLY
(a) Place a new gasket so that the rear mark is toward the rear side.
(b) Install the intake manifold with the 10 bolts and 2 nuts.
Torque: 21 N·m (210 kgf·cm, 15 ft·lbf)
(c) Connect the 2 vacuum hoses to the TVV.
14. INSTALL HEATER INLET PIPE AND HOSE
Install the heater hose to the cylinder head, and connect the
pipe to the intake manifold with the 2 bolts. Torque: 21 N·m (210 kgf·cm, 15 ft·lbf)
15. INSTALL EGR PIPE
(a) Temporarily install the union nut to the EGR valve.
(b) Install a new gasket and the EGR pipe to the cylinder head with the 2 bolts.
Torque: 21 N·m (210 kgf·cm, 15 ft·lbf)
(c) Tighten the union nut. Torque: 78 N·m (800 kgf·cm, 58 ft·lbf)
16. INSTALL WATER OUTLET
Install a new gasket and the water outlet with the 2 nuts. Torque: 21 N·m (210 kgf·cm, 15 ft·lbf)
17. INSTALL GENERATOR BRACKET
Install the generator bracket with the 2 bolts. Torque: 43 N·m (440 kgf·cm, 32 ft·lbf)
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EM−62
−
ENGINE MECHANICAL CYLINDER HEAD
1996 LAND CRUISER (RM451U)
(h) Connect the engine wire to the intake manifold and cylin-
der block with the 2 bolts.
(i) Connect the PNP switch connector.
(j) Connect the 2 heated oxygen sensor connectors.
(k) Connect the connectors.
(1) Connect the Knock sensor connector.
(2) Connect the oil level sensor connector.
(3) Connect the 2 connectors to tthe ransmission.
(4) Connect the starter connector.
(l) Connect the engine wire to the cylinder block with the bolt.
(m) Connect the connectors.
(1) Connect the ECT sender gauge connector.
(2) Connect the ECT cut switch connector.
(3) Connect the ECT sensor connector.
(4) Connect the knock sensor connector.
(5) Connect the crankshaft position sensor connector.
19. CONNECT FUEL INLET HOSE
Connect the fuel inlet hose to the fuel filter with 2 new gaskets
and the union bolt. Torque: 29 N·m (300 kgf·cm, 22 ft·lbf)
20. INSTALL INTAKE MANIFOLD STAY
Install the intake manifold stay with the 2 bolts. Torque: 36 N·m (360 kgf·cm, 26 ft·lbf)
21. INSTALL OIL DIPSTICKS AND GUIDES FOR ENGINE AND TRANSMISSION
(a) Install a new O−ring to the dipstick guide.
(b) Apply a light coat of engine oil on the O −ring.
(c) Push in the dipstick guide into the guide hole of the oil pan.
(d) Install the dipstick guide with the 2 bolts. Torque: 20 N·m (200 kgf·cm, 14 ft·lbf)
22. INSTALL THROTTLE BODY (See page SF−48)
23. INSTALL GENERATOR AND DRIVE BELTS (See page CH−19 )
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