1996 TOYOTA LAND CRUISER radiator

EM−64
−
ENGINE MECHANICAL CYLINDER HEAD
1996 LAND CRUISER (RM451U)
39. INSTALL AIR CLEANER HOSE AND CAP
40. INSTALL BATTERY TRAY AND BATTERY
(a) Install the battery tray with the 5 bolts.
(b) Connect the ground strap with the bolt.
(c) Install the battery and hold−down clamp with the nuts.
(d) Connect the battery cables.
41. FILL RADIATOR WITH ENGINE COOLANT
42. START ENGINE AND CHECK FOR LEAKS
43. ADJUST IGNITION TIMING (See page EM−10)
44. PERFORM ROAD TEST
Check for abnormal noise, shock, slippage, correct shift points
and smooth operation.
45. RECHECK ENGINE COOLANT LEVEL
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EM1ED−02
−
ENGINE MECHANICAL ENGINE UNIT
EM−69
1996 LAND CRUISER (RM451U)
REMOVAL
1. DRAIN ENGINE COOLANT
2. DRAIN ENGINE OIL
3. REMOVE HOOD
4. 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.
5. REMOVE RADIATOR GRILLE
Remove the 5 screws, clip and radiator grille.
6. REMOVE RADIATOR (See page CO−14 )
7. DISCONNECT OIL COOLER HOSE FROM OIL COOL- ER PIPE
8. REMOVE AIR CLEANER HOSE AND CAP
9. REMOVE AIR CLEANER CASE
10. DISCONNECT CRUISE CONTROL ACTUATOR CABLE FROM THROTTLE BODY
11. DISCONNECT ACCELERATOR CABLE FROM THROTTLE BODY
12. DISCONNECT HEATER HOSES
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EM−70
−
ENGINE MECHANICAL ENGINE UNIT
1996 LAND CRUISER (RM451U)
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. DISCONNECT BRAKE BOOSTER VACUUM HOSE
15. DISCONNECT EVAP HOSE
16. DISCONNECT FUEL HOSES
(a) Disconnect the fuel return hose.
(b) Remove the union bolt and 2 gaskets, and disconnect the
fuel inlet hose from the fuel filter.
17. DISCONNECT WIRES AND CONNECTORS
(a) Disconnect the 2 heated oxygen sensor connectors.
(b) Disconnect the DLC1 clamp.
(c) Disconnect the 2 oil pressure gauge connectors.
(d) Disconnect the generator wire and connector.
(e) Disconnect the connector on the intake manifold from the
fender apron.
(f) Disconnect the high−tension cord from the ignition coil.
(g) Disconnect the ground strap from the No. 1 engine hang-
er.
(h) Disconnect the ground strap from the air intake chamber.
(i) Disconnect the starter wire.
(j) Disconnect the ground cable from the cylinder block.
18. 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.
19. REMOVE RADIATOR PIPE
(a) Remove the 2 nuts holding the radiator pipe to the No. 1 oil pan.
(b) Disconnect the No. 2 radiator hose from the water inlet and remove the radiator pipe.
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EM−80
−
ENGINE MECHANICAL ENGINE UNIT
1996 LAND CRUISER (RM451U)
19. CONNECT ENGINE WIRE TO CABIN
(a) Push in the engine wire through the cowl panel.
(b) Connect the connectors.
(1) Connect the 3 connectors to the ECM.
(2) Connect the 2 connectors to the cowl wire.
(c) Connect the A/C amplifier with the screw.
(d) Install the speaker panel with the screw.
(e) Install the glove compartment door with the 2 screws.
20. CONNECT PS RETURN HOSE
Connect the return hose to the PS reservoir tank.
21. CONNECT PS PRESSURE HOSE
Connect the PS pressure hose with 2 new gaskets and the
union bolt. Torque: 56 N·m (575 kgf·cm, 42 ft·lbf)
22. 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)
23. 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).
24. CONNECT WIRES AND CONNECTORS
(a) Connect the 2 heated oxygen sensor connectors.
(b) Connect the DLC1 clamp.
(c) Connect the 2 oil pressure gauge connectors.
(d) Connect the generator wire and connector.
(e) Connect the connector on the intake manifold to the fend-
er apron.
(f) Connect the high −tension cord to the ignition coil.
(g) Connect the ground strap to the No. 1 engine hanger.
(h) Connect the ground strap to the air intake chamber.
(i) Connect the starter wire.
(j) Connect the ground cable to the cylinder block.
25. CONNECT FUEL HOSES
(a) Connect the fuel inlet hose to the fuel filter with 2 new gas-
kets and the union bolt.
Torque: 29 N·m (300 kgf·cm, 22 ft·lbf)
(b) Connect the fuel return hose.
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−
ENGINE MECHANICAL ENGINE UNIT
EM−81
1996 LAND CRUISER (RM451U)
26. CONNECT EVAP HOSE
27. CONNECT BRAKE BOOSTER VACUUM HOSE
28. 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.
29. CONNECT HEATER HOSES
30. CONNECT ACCELERATOR CABLE TO THROTTLE BODY
31. CONNECT CRUISE CONTROL ACTUATOR CABLE TO
THROTTLE BODY
32. INSTALL AIR CLEANER CASE
33. INSTALL AIR CLEANER HOSE AND CAP
34. CONNECT OIL COOLER HOSE TO OIL COOLER PIPE
35. INSTALL RADIATOR (See page CO−16)
36. INSTALL RADIATOR GRILLE
Install the radiator grille with the 5 screws and clip.
37. INSTALL BATTERY TRAY AND BATTERY
(a) Install the battery tray with the 5 bolts.
(b) Connect the ground strap with the bolt.
(c) Install the battery and hold−down clamp with the nuts.
(d) Connect the battery cables.
38. FILL WITH ENGINE OIL
39. FILL RADIATOR WITH ENGINE COOLANT
40. START ENGINE AND CHECK FOR LEAKS
41. CHECK AUTOMATIC TRANSMISSION FLUID LEVEL
42. CHECK IGNITION TIMING (See page EM−10)
43. INSTALL HOOD
44. PERFORM ROAD TEST
Check for abnormal noise, shock, slippage, correct shift points
and smooth operation.
45. RECHECK ENGINE COOLANT AND ENGINE OIL LEV-
ELS
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LU0KG−02
−
LUBRICATION OIL PUMP
LU−5
1996 LAND CRUISER (RM451U)
REMOVAL
HINT:
When repairing the oil pump, the oil pan and strainer should be
removed and cleaned.
1. DRAIN ENGINE OIL
2. REMOVE ENGINE UNDER COVER
3. DRAIN ENGINE COOLANT
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 )
9. DISCONNECT OIL COOLER PIPE BRACKET FROM NO.1 OIL PAN
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LU−14
−
LUBRICATION OIL PUMP
1996 LAND CRUISER (RM451U)
Install the 6 bolts.
Torque: 72 N·m (730 kgf·cm, 53 ft·lbf)
11. 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)
12. CONNECT OIL COOLER PIPE BRACKET TO NO.1 OIL
PA N
13. INSTALL CYLINDER HEAD(See page EM−54)
14. 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)
15. 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)
16. 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).
17. INSTALL RADIATOR (See page CO−16 )
18. INSTALL ENGINE UNDER COVER
19. FILL WITH ENGINE OIL
20. START ENGINE AND CHECK FOR LEAKS
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LU08Z−04
P08343
Adhesive
−
LUBRICATION OIL COOLER
LU−19
1996 LAND CRUISER (RM451U)
INSTALLATION
1. INSTALL RELIEF VALVE
Install the relief valve, spring and a new gasket with the plug.
Torque: 37 N·m (375 kgf·cm, 27 ft·lbf)
2. ASSEMBLE OIL COOLER AND OIL COOLER COVER
Install 2 new gaskets and the oil cooler to the oil cooler cover
with the 4 nuts. Torque: 17 N·m (170 kgf·cm, 12 ft·lbf)
3. INSTALL OIL COOLER AND OIL COOLER COVER ASSEMBLY
Install a new gasket, the oil cooler and oil cooler cover assembly
with the 10 bolts and 2 nuts. Torque: 21 N·m (210 kgf·cm, 15 ft·lbf)
4. INSTALL OIL PRESSURE SWITCH
(a) Apply adhesive to 2 or 3 threads of the oil pressure switch.
Adhesive:
Part No. 08833 −00080, THREE BOND 1344,
LOCTITE 242 or equivalent
(b) Install the oil pressure switch.
5. INSTALL NO.1 EXHAUST MANIFOLD
(a) Install a new gasket and the exhaust manifold with the 6 nuts.
Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)
(b) Install the heat insulator with the 3 bolts. Torque: 19 N·m (195 kgf·cm, 14 ft·lbf)
6. INSTALL FRONT EXHAUST PIPE
(a) Install 2 new gaskets and the front exhaust pipe with the 4 nuts.
Torque: 63 N·m (630 kgf·cm, 46 ft·lbf)
(b) Install the No.1 support bracket with the 2 bolts. Torque: 24 N·m (240 kgf·cm, 17 ft·lbf)
(c) Connect the clamp and tighten the clamp bolt. Torque: 19.5 N·m (195 kgf·cm, 14 ft·lbf)
(d) Connect the front exhaust pipe to the rear TWC with a new gasket, 2 bolts and 2 nuts.
Torque: 46 N·m (470 kgf·cm, 34 ft·lbf)
7. INSTALL AIR CLEANER CAP AND HOSE
8. FILL RADIATOR WITH ENGINE COOLANT
9. START ENGINE AND CHECK FOR LEAKS
10. CHECK ENGINE OIL
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