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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
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−
COOLING RADIATOR
CO−15
1996 LAND CRUISER (RM451U)
10. REMOVE RADIATOR
(a) Remove the 2 bolts, 2 nuts and radiator.
(b) Remove the 4 nuts and 2 radiator brackets.
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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
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EM0494
−
ENGINE MECHANICAL VALVE CLEARANCE
EM−7
510
Author: Date:
1996 LAND CRUISER (RM451U)
9. Rear valves of No. 6 cylinder
ADJUST VALVE CLEARANCE
(a) Remove the distributor (See page IG−10).
(b) Remove the camshafts (See page EM−28).
(c) Remove the adjusting shim with a small screwdriver.
(d) Determine the replacement adjusting shim size by follow- ing the Formula or Charts:
Using a micrometer, measure the thickness of the
removed shim.
Calculate the thickness of a new shim so that the
valve clearance comes within specified value.
T ....... Thickness of removed shim
A ....... Measured valve clearance
N ....... Thickness of new shim
Intake: N = T + (A − 0.20 mm (0.008 in.))
Exhaust: N = T + (A − 0.30 mm (0.012 in.))
Select a new shim with a thickness as close as pos-
sible to the calculated value.
HINT:
Shims are available in 17 sized in increments of 0.05 mm
(0.0020 in.), from 2.50 mm (0.0984 in.) to 3.30 mm (0.1299 in.).
(e) Place a new adjusting shim on the valve lifters.
(f) Install the camshafts (See page EM−54 ).
(g) Recheck the valve clearance.
(h) Install the distributor (See page IG−11 ).
10. REINSTALL CYLINDER HEAD COVER
(a) Install the gasket to the cylinder head cover.
(b) Install the cylinder head cover with the 13 bolts.
11. RECONNECT HIGH −TENSION CORDS TO SPARK
PLUGS (See page IG−1 )
12. RECONNECT HEA TER VALVE AND ENGINE WIRE TO
COWL PANEL
(a) Connect the heater valve with the 2 bolts.
(b) Connect the ground strap and engine wire with the 2 bolts.
13. REINSTALL THROTTLE BODY (See page SF−48 )
14. REFILL RADIATOR WITH ENGINE COOLANT
15. CHECK AND ADJUST IGNITION TIMING (See page EM−10 )
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EM1E9−01
−
ENGINE MECHANICAL TIMING CHAIN
EM−13
1996 LAND CRUISER (RM451U)
REMOVAL
1. DRAIN ENGINE OIL
2. DRAIN ENGINE COOLANT
3. REMOVE ENGINE UNDER COVER
4. REMOVE RADIATOR (See page CO−14 )
5. DISCONNECT A/C COMPRESSOR AND BRACKET
(a) Loosen the idler pulley nut and adjusting bolt, and remove
the drive belt.
(b) Remove the 4 mounting bolts, and disconnect the com- pressor from the bracket.
HINT:
Put aside the compressor, and suspend it.
(c) Remove the 5 bolts and A/C compressor bracket.
6. REMOVE RADIATOR PIPE
(a) Disconnect the No. 2 radiator hose from the water inlet.
(b) Remove the 2 nuts and radiator pipe.
7. REMOVE WATER PUMP
Remove the 4 bolts, 2 nuts, water pump and gasket.
8. REMOVE CYLINDER HEAD (See page EM−28 )
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−
ENGINE MECHANICAL TIMING CHAIN
EM−23
1996 LAND CRUISER (RM451U)
15. INSTALL OIL LEVEL SENSOR
(a) Install a new gasket to the level sensor.
(b) Install the level sensor with the 4 bolts.
Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf)
16. CONNECT OIL COOLER PIPE BRACKET TO NO. 1 OIL
PA N
17. INSTALL CYLINDER HEAD (See page EM−54 )
NOTICE:
However, for the installation of the camshaft timing gear
and timing chain, follow the below procedure. Align the
blight link of the timing chain and camshaft timing gear
mark, and install them to the camshaft.
18. INSTALL WATER PUMP
Install a new gasket and water pump with the 4 bolts and 2 nuts.
Torque: 21 N·m (210 kgf·cm, 15 ft·lbf)
19. INSTALL RADIATOR PIPE
(a) Connect the No.2 radiator hose to the water inlet.
(b) Install the 2 nuts holding the radiator pipe to the No.1 oil
pan.
Torque: 21 N·m (210 kgf·cm, 15 ft·lbf)
20. INSTALL A/C COMPRESSOR AND BRACKET
(a) Install the A/C compressor bracket with the 5 bolts.
Torque: 37 N·m (375 kgf·cm, 27 ft·lbf)
(b) Install the A/C compressor with the 4 bolts. Torque: 25 N·m (250 kgf·cm, 18 ft·lbf)
(c) Install and adjust the drive belt (See page CH−2).
21. INSTALL RADIATOR (See page CO−16 )
22. FILL ENGINE WITH OIL
23. INSTALL ENGINE UNDER COVER
24. START ENGINE AND CHECK FOR LEAKS
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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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−
ENGINE MECHANICAL CYLINDER HEAD
EM−63
1996 LAND CRUISER (RM451U)
24. CONNECT NO. 3 WATER BYPASS HOSE
25. CONNECT RADIATOR INLET HOSE
26. CONNECT PS RESERVOIR TANK
Connect the reservoir tank with the 3 bolts.
Torque: 20 N·m (200 kgf·cm, 14 ft·lbf)
27. INSTALL DISTRIBUTOR (See page IG−11)
28. INSTALL NO. 2 AND NO. 3 CYLINDER HEAD COVERS
Install the head covers with the 4 bolts.
29. CONNECT HEATER VALVE AND ENGINE WIRE TO COWL PANEL
(a) Connect the heater valve with the 2 bolts.
(b) Connect the engine wire and ground strap with the 2 bolts.
30. CONNECT HEATER HOSES
31. CONNECT FUEL RETURN HOSE
32. CONNECT EVAP HOSE
33. CONNECT BRAKE BOOSTER VACUUM HOSE
34. CONNECT CONNECTOR ON INTAKE MANIFOLD TO LH FENDER APRON
35. CONNECT ENGINE GROUND STRAPS
(a) Connect the ground strap to the No. 1 engine hanger.
(b) Connect the ground strap to the air intake chamber.
36. CONNECT THROTTLE CABLE TO THROTTLE BODY
37. CONNECT ACCELERATOR CABLE TO THROTTLE
BODY
38. CONNECT CRUISE CONTROL ACTUATOR CABLE TO
THROTTLE BODY
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