1996 TOYOTA LAND CRUISER lock

SR16E−03
−
STEERING TILT STEERING COLUMN
SR−19
1996 LAND CRUISER (RM451U)
INSTALLATION
1. INSTALL STEERING COLUMN ASSEMBLY
(a) Torque the 2 column assembly set nuts and 2 set bolts.
Torque:25 N·m (250 kgf·cm, 18 ft·lbf)
(b) Connect the 3 connectors.
2. INSTALL SLIDING YOKE SUB −ASSEMBLY
Temporarily tighten the bolt A.
3. CONNECT SLIDING YOKE SUB−ASSEMBLY
(a) Align the matchmarks on the yoke sub−assembly and
worm gear valve body shaft.
(b) Torque the bolt B. Torque: 34 N·m (350 kgf·cm, 25 ft·lbf)
(c) Torque the bolt A.
Torque: 34 N·m (350 kgf·cm, 25 ft·lbf)
4. INSTALL LINK JOINT PROTECTOR
Torque the 2 bolts. Torque: 12 N·m (120 kgf·cm, 9 ft·lbf)
5. TORQUE 4 COLUMN HOLE COVER SET BOLTS Torque: 13 N·m (130 kgf·cm, 9 ft·lbf)
6. INSTALL COMBINATION SWITCH WITH SPIRAL CABLE
(a) Tighten the 4 screws.
(b) Connect the airbag connector.
(c) Connect the 2 connectors.
7. INSTALL UPPER AND LOWER COLUMN COVERS
Tighten the 5 screws.
8. INSTALL NO.2 HEATER TO REGISTER DUCT
9. INSTALL INSTRUMENT LOWER FINISH PANEL
(a) Tighten the 4 panel set screws.
(b) Connect the hood lock control cable and fuel lid control cable.
10. CENTER SPIRAL CABLE
(a) Check that the front wheels are facing straight ahead.
(b) Turn the cable counterclockwise by hand until it becomes harder to turn the cable.
(c) Then rotate the cable clockwise about 3 turns to align the
red mark.
HINT:
The cable will rotate about 3 turns to either left or right of the
center.
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R11234
Rear Housing
Brass Bar
R11235
Rear Housing Wood Block
R08075
Extension Bar
R08074
−
STEERING POWER STEERING VANE PUMP
SR−25
1996 LAND CRUISER (RM451U)
(b) Using a brass bar and hammer, tap the housing so that
the spring force of the wave washer pushes the housing
forward.
(c) Gently tap the PS pump assembly on a wood block and remove the housing and washer.
(d) Remove the O−ring from the housing.
6. REMOVE SIDE REAR PLATE
(a) Gently tap the PS pump assembly on a wood block and remove the plate.
(b) Remove the O−ring from the plate.
7. REMOVE CAM RING, VANE PUMP ROTOR AND 10 VANE PLATES
NOTICE:
Be careful not to scratch the cam ring, rotor or vane plates.
8. REMOVE SHORTER STRAIGHT PIN
Remove the pin from the side front plate.
9. REMOVE VANE PUMP SHAFT WITH BEARING
(a) Using snap ring pliers, remove the snap ring.
(b) Using an extension bar and hammer, tap out the shaft
with the bearing.
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R12473
SR168−01
SR0097
−
STEERING STEERING WHEEL
SR−7
1058
Author: Date:
1996 LAND CRUISER (RM451U)
STEERING WHEEL
INSPECTION
1. CHECK STEERING WHEEL FREEPLAY
(a) With the vehicle stopped and tires pointed straight ahead,
rock the steering wheel gently back and forth with light fin-
ger pressure.
(b) Freeplay should not exceed the maximum. Maximum freeplay: 40 mm (1.58 in.)
If the freeplay exceeds the maximum, adjust it in the following
procedure.
2. ADJUST STEERING GEAR
(a) Point the front wheels straight ahead.
(b) Loosen the adjusting screw lock nut.
(c) Turn the cross shaft adjusting screw clockwise to de- crease steering wheel freeplay and counterclockwise to
increase it.
HINT:
Turn the adjusting screw in small increments and check the
freeplay between each adjustment.
(d) Turn the steering wheel half way around in both direc- tions.
(e) Check that the freeplay is correct and steering is smooth and without rough spots.
(f) Torque the adjusting screw lock nut (See page SR−41).
3. CHECK STEERING EFFORT
(a) Center the steering wheel.
(b) Remove the steering wheel pad (See page SR−11).
(c) Start the engine and run it at idle.
(d) Measure the steering effort in both directions.
Reference: 8.3 N·m (85 kgf·cm, 73 in.·lbf)
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SR16N−01
SR−36
−
STEERING POWER STEERING GEAR
1996 LAND CRUISER (RM451U)
DISASSEMBLY
NOTICE:
When using a vise, do not overtighten it.
1. SECURE PS GEAR ASSEMBLY IN VISE
Secure the gear assembly on SST and clamp SST in a vise. SST 09630−00014 (09631 −00142)
2. REMOVE ADJUSTING SCREW LOCK NUT AND SEAL
WASHER
3. REMOVE SIDE COVER
(a) Remove the 4 bolts.
(b) Turn the cross shaft adjusting screw clockwise until the cover comes off.
(c) Remove the O−ring from the cover.
4. REMOVE CROSS SHAFT
Using a plastic hammer, tap on the cross shaft end and pull out
the shaft.
5. REMOVE POWER PISTON PLUNGER GUIDE NUT, COMPRESSION SPRING, POWER PISTON PLUNGER
AND POWER PISTON PLUNGER GUIDE
(a) Using a hexagon wrench (10 mm), remove the plunger
guide nut.
(b) Remove the O−ring from the plunger guide nut.
6. REMOVE WORM GEAR VALVE BODY ASSEMBLY
(a) Remove the 4 bolts.
(b) Using SST, turn the valve body shaft clockwise with hold-
ing the worm gear by your finger so it cannot move.
SST 09616−00010
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SR16O−01
Z14503
Dial Indicator30 mm
(1.18 in.)
Z14504
Dial Indicator
Z10600
Z06211
SR−38
−
STEERING POWER STEERING GEAR
1996 LAND CRUISER (RM451U)
INSPECTION
NOTICE:
When using a vise, do not overtighten it.
1. INSPECT BALL CLEARANCE
Using a dial indicator, check the ball clearance. Move the worm
gear up and down. Maximum clearance: 0.15 mm (0.0059 in.)
2. INSPECT CROSS SHAFT ADJUSTING SCREW THRUST CLEARANCE
Using a dial indicator, measure the thrust clearance. Standard clearance: 0.03 − 0.05 (0.0012 − 0.0020 in.)
3. IF NECESSARY, ADJUST CROSS SHAFT ADJUSTING SCREW THRUST CLEARANCE
(a) Using a chisel and hammer, unstake the No.1 lock nut.
(b) Using SST, remove the No.1 lock nut. SST 09630−00014 (09631 −00051)
(c) Using a screwdriver, adjust the adjusting screw for correct thrust clearance.
(d) Using the SST, tighten a new lock nut.
(e) Using a chisel and hammer, stake the lock nut.
4. IF NECESSARY, REPLACE OIL SEAL, METAL SPACER AND TEFLON RING
(a) Using a screwdriver, pry out the oil seal from the gear
housing.
(b) Using snap ring pliers, remove the snap ring from the gear
housing.
(c) Remove the metal spacer, teflon ring and O −ring from the
gear housing.
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SR−42
−
STEERING POWER STEERING GEAR
1996 LAND CRUISER (RM451U)
4. DETERMINE CENTER POSITION
(a) Using SST, turn the worm gear valve body shaft so full
lock in both directions and determine the exact center.
SST 09616−00010
(b) Place matchmarks on the worm gear valve body shaft and
worm gear valve body housing to show neutral position.
5. INSTALL CROSS SHAFT AND SIDE COVER
(a) Coat a new O −ring with power steering fluid and install it
on the side cover.
(b) Assemble the cross shaft to the side cover.
HINT:
Fully loosen the cross shaft adjusting screw.
(c) Install and push the cross shaft into the gear housing so that the center teeth mesh together.
(d) Torque the 4 bolts in a diagonal pattern. Torque: 61 N·m (620 kgf·cm, 45 ft·lbf)
6. ADJUST TOTAL PRELOAD
(a) Install SST with a torque wrench on the worm gear valve body shaft.
SST 09616−00010
(b) Turn the cross shaft adjusting screw until the preload is
within specification.
Preload (Turning):
0.74 − 10.8 N·m (7.5 − 11.0 kgf·cm, 6.5 − 9.6 in.·lbf)
7. INSTALL NEW SEAL WASHER
8. INSTALL ADJUSTING SCREW LOCK NUT
Torque the lock nut while holding the cross shaft adjusting
screw. Torque: 46 N·m (470 kgf·cm, 34 ft·lbf)
9. CHECK TOTAL PRELOAD
Using SST and a torque wrench, check total preload. SST 09616−00010
Total preload (Turning):
0.74 − 1.08 N·m (7.5 − 11.0 kgf·cm, 6.5 − 9.6 in.·lbf)
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SS1EO−04
SS−4
−
SERVICE SPECIFICATIONS ENGINE MECHANICAL
127
Author: Date:
1996 LAND CRUISER (RM451U)
ENGINE MECHANICAL
SERVICE DATA
Compression
pressureat 250 rpm STD
Minimum
Difference of pressure between each cylinder1,176 kPa (12.0 kgf/cm2, 171 psi) or more
883 kPa (9.0 kgf/cm2, 128 psi)
98 kPa (1.0 kgf/cm2, 14 psi) or less
Valve clearanceat cold Intake Exhaust0.15 − 0.25 mm (0.006 − 0.010 in.)
0.25 − 0.35 mm (0.010 − 0.014 in.)
Ignition timingw/ Terminals TE1 and E1 connected3° BTDC @ idle
Idle speed−650 ± 50 rpm
Cylinder headWarpage
Cylinder block side Maximum
Manifold side Maximum
Valve seat
Refacing angle Intake
Exhaust
Contacting angle
Contacting width Intake
Exhaust
Cylinder head bolt outside diameter STD
Minimum
0.15 mm (0.0059 in.)
0.10 mm (0.0039 in.)
30°, 45° , 75°
45 °, 75°
45 °
1.2 − 1.6 mm (0.047 − 0.063 in.)
1.0 − 1.4 mm (0.039 − 0.055 in.)
10.85 − 11.00 mm (0.4272 − 0.4331 in.)
10.6 mm (0.417 in.)
Valve guide
bushingInside diameter
Outside diameter (for repair part) STD O/S 0.05
Protrusion height7.010 − 7.030 mm (0.2760 − 0.2768 in.)
11.492 − 11.513 mm (0.4524 − 0.4533 in.)
11.542 − 11.563 mm (0.4544 − 0.4522 in.)
8.2 − 8.6 mm (0.323 − 0.339 in.)
ValveValve overall length STD Intake
Exhaust
Minimum Intake Exhaust
Valve face angle
Stem diameter Intake
Exhaust
Stem oil clearance STD Intake
Exhaust
Maximum Intake
Exhaust
Margin thickness STD
Minimum98.4 mm (3.874 in.)
97.9 mm (3.854 in.)
97.9 mm (3.854 in.)
97.4 mm (3.835 in.)
44.5 °
6.970 − 6.985 mm (0.2744 − 0.2750 in.)
6.965 − 6.980 mm (0.2742 − 0.2748 in.)
0.025 − 0.060 mm (0.0010 − 0.0024 in.)
0.030 − 0.065 mm (0.0012 − 0.0026 in.)
0.08 mm (0.0031 in.)
0.10 mm (0.0039 in.)
1.2 mm (0.047 in.)
1.0 mm (0.039 in.)
Valve springDeviation Maximum
Free length
Installed tension at 36.5 mm (1.437 in.)2.0 mm (0.079 in.)
43.94 − 45.06 mm (1.7299 − 1.7740 in.)
214 − 238 N (21.8 − 24.2 kgf, 48.1 − 53.4 lbf)
Valve lifterLifter diameter
Lifter bore diameter
Oil clearance STD
Maximum33.966 − 33.976 mm (1.3372 − 1.3376 in.)
34.000 − 34.021 mm (1.3386 − 1.3394 in.)
0.024 − 0.055 mm (0.0009 − 0.0022 in.)
0.07 mm (0.0028 in.)
ManifoldWarpage Maximum0.30 mm (0.0118 in.)
Air intake chamberWarpageMaximum0.30 mm (0.0118 in.)
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−
SERVICE SPECIFICATIONS ENGINE MECHANICAL
SS−5
128
Author: Date:
1996 LAND CRUISER (RM451U)
Camshaft
Thrust clearance
STD
Maximum
Journal oil clearance STD
Maximum
Journal diameter
Circle runout Maximum
Cam lobe height STD
Minimum
Camshaft gear backlash STD
Maximum
Camshaft gear spring end free distance0.030 − 0.080 mm (0.0012 − 0.0031 in.)
0.10 mm (0.0039 in.)
0.025 − 0.062 mm (0.0010 − 0.0024 in.)
0.10 mm (0.0039 in.)
26.959 − 26.975 mm (1.0614 − 1.0620 in.)
0.06 mm (0.0024 in.)
50.61 − 50.71 mm (1.9925 − 1.9965 in.)
50.51 mm (1.9886 in.)
0.020 − 0.200 mm (0.0008 − 0.0079 in.)
0.30 mm (0.0188 in.)
18.2 − 18.8 mm (0.712 − 0.740 in.)
Spark plug tubeProtrusion45.5 mm (1.791 in.)
Oil pump drive
shaft gearThrust clearance STD
Maximum0.040 − 0.160 mm (0.0016 − 0.0063 in.)
0.30 mm (0.0188 in.)
Chain and timing
gearChain length at 16 links Maximum
Camshaft timing gear wear (w/ Chain) Minimum
Crankshaft timing gear wear (w/ Chain) Minimum146.6 mm (5.772 in.)
126.0 mm (4.961 in.)
65.4 mm (2.575 in.)
Chain tensioner
slipper and vibra-
tion damperWearMaximum1.0 mm (0.039 in.)
Cylinder blockCylinder head surface warpageMaximum
Cylinder bore diameter STD Mark 1
2
3
Maximum STD
O/S 0.50
O/S 1.00
Main bearing bolt outside diameter STD
Minimum0.05 mm (0.0020 in.)
100.000 − 100.010 mm (3.9370 − 3.9374 in.)
100.010 − 100.020 mm (3.9374 − 3.9378 in.)
100.020 − 100.030 mm (3.9378 − 3.9382 in.)
100.23 mm (3.9461 in.)
100.73 mm (3.9658 in.)
101.23 mm (3.9854 in.)
10.85 − 11.00 mm (0.4271 − 0.4331 in.)
10.6 mm (0.417 in.)
Piston and piston
ringPiston diameter STD Mark 1
2
3
O/S 0.50
O/S 1.00
Piston oil clearance STD
Piston ring groove clearance No. 1
No. 2
Piston ring end gap STD No. 1
No. 2
Oil
Maximum No. 1 No. 2Oil99.950 − 99.960 mm (3.9350 − 3.9354 in.)
99.960 − 99.970 mm (3.9354 − 3.9358 in.)
99.970 − 99.980 mm (3.9358 − 3.9362 in.)
100.450 − 100.480 mm (3.9547 − 3.9559 in.)
100.950 − 100.980 mm (3.9744 − 3.9756 in.)
0.040 − 0.060 mm (0.0016 − 0.0024 in.)
0.040 − 0.080 mm (0.0016 − 0.0031 in.)
0.300 − 0.070 mm (0.0012 − 0.0028 in.)
0.300 − 0.520 mm (0.0118 − 0.0205 in.)
0.450 − 0.670 mm (0.0177 − 0.0264 in.)
0.150 − 0.520 mm (0.0059 − 0.0205 in.)
1.12 mm (0.0441 in.)
1.17 mm (0.0461 in.)
1.12 mm (0.0441 in.)
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