1996 TOYOTA LAND CRUISER Over drive

SR16D−02
R09496
SST
SR−16
−
STEERING TILT STEERING COLUMN
1996 LAND CRUISER (RM451U)
REASSEMBLY
NOTICE:
When using a vise, do not overtighten it.
1. COAT WITH MOLYBDENUM DISULFIDE LITHIUM BASE GREASE (See page SR−9 )
2. INSTALL MAIN SHAFT ASSEMBLY
(a) Install a new bearing, bearing thrust collar and compres- sion spring to the shaft assembly.
(b) Install the shaft assembly into the column upper tube.
(c) Using SST, compress the compression spring. SST 09950−40010 (09957 −04010, 09958−04010)
NOTICE:
Do not bend the universal joint of the main shaft more than
20 °.
(d) Using snap ring pliers, install a new snap ring.
3. INSTALL TURN SIGNAL BRACKET
Torque the 2 bolts. Torque: 4.9 N·m (50 kgf·cm, 43 in.·lbf)
4. SELECT TILT NO.2 BOLTS
Select the bolt with plain thread end when the column upper
tube mark is 2, and the bolt with the hollow −tipped thread end
when the mark is 1.
NOTICE:
Select the bolt type to match each number marked in the
squares on the upper tube.
5. INSTALL COLUMN UPPER TUBE WITH MAIN SHAFT ASSEMBLY
(a) Install the collar to the shaft assembly.
(b) Install a new snap ring.
(c) Install the upper tube with the shaft assembly into the col-
umn lower tube.
(d) Using a plastic hammer, drive in the 2 tilt No.2 bolts.
6. INSTALL TILT LEVER LOCK SHAFT, TILT LEVER AS- SEMBLY, TILT SUB LEVER AND TILT LEVER
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SR16H−01
R08084
R08066
Soft Jaws
R13187
Press
SST
SST
R08067
Screwdriver
SR−24
−
STEERING POWER STEERING VANE PUMP
1996 LAND CRUISER (RM451U)
DISASSEMBLY
NOTICE:
When using a vise, do not overtighten it.
1. MEASURE POWER STEERING VANE PUMP ROTAT-
ING TORQUE
(a) Check that the pump rotates smoothly without abnormal noise.
(b) Using a torque wrench, check the pump rotating torque. Rotation torque:
0.3 N·m (2.8 kgf·cm, 2.4 in.·lbf) or less
2. REMOVE SUCTION PORT UNION
(a) Remove the bolt.
(b) Remove the O−ring from the union.
3. REMOVE VANE PUMP DRIVE GEAR
(a) Using soft jaws on a vise, clamp the gear in the vise.
NOTICE:
Be careful not to damage the gear.
(b) Remove the gear set nut.
(c) Using SST, press out the gear.
SST 09527−10011
NOTICE:
Be careful not to damage the gear. To avoid dropping the
PS pump assembly, support the pump assembly with your
hand.
(d) Remove the woodruff key from the vane pump shaft.
4. REMOVE PRESSURE PORT UNION, FLOW CONTROL
VALVE AND SPRING
Remove the O−ring from the union.
5. REMOVE REAR HOUSING AND WAVE WASHER
(a) Using 2 screwdrivers, remove the snap ring.
NOTICE:
Take care not to damage the housing.
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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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SR2804
−
STEERING POWER STEERING GEAR
SR−39
1996 LAND CRUISER (RM451U)
(d) Coat a new O− ring and metal spacer with power steering
fluid and install them.
(e) Using snap ring pliers, install a new snap ring.
(f) Coat a new teflon ring with power steering fluid.
(g) Form a teflon ring into a heart shape and install it with
hand.
(h) Using SST, form the teflon ring.
SST 09630−00014 (09631 −00121)
NOTICE:
The teflon ring must be squeezed before inserting the
cross shaft or damage will result.
(i) Coat a new oil seal with power steering fluid.
(j) Using SST, press in the oil seal to the gear housing. SST 09950−60010 (09951 −00340, 09951−00450)
09950 −70010 (09951 −07200)
NOTICE:
Make sure you install the oil seal facing the correct direc-
tion.
5. IF NECESSARY, REPLACE TEFLON RING AND O −
RING
(a) Using a screwdriver, remove the teflon ring and O −ring
from the worm gear valve body assembly.
NOTICE:
Be careful not to damage the worm gear valve body assem-
bly.
(b) Coat a new O −ring with power steering fluid and install it.
(c) Expand a new teflon ring with your fingers.
NOTICE:
Be careful not to overexpand the teflon ring.
(d) Install the teflon ring.
(e) Coat the teflon ring with power steering fluid and snug it down with piston ring compressor for 5 − 7 minutes.
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SS1EP−01
−
SERVICE SPECIFICATIONS ENGINE MECHANICAL
SS−7
1996 LAND CRUISER (RM451U)
TORQUE SPECIFICATION
Part tightenedN·mkgf·cmft·lbf
Distributor x Cylinder head1818013
No. 1 engine hanger x Cylinder head4142030
No. 2 engine hanger x Cylinder head4142030
Air intake chamber x Intake manifold2121015
Intake manifold x Cylinder head2121015
Heater inlet pipe x Intake manifold2121015
EGR pipe x Cylinder head2121015
EGR pipe x EGR valve Union nut7880058
Water outlet x Cylinder head2121015
Generator bracket x Cylinder head4344032
Cylinder head x Cylinder block 1st
2nd 3rd39
Turn 90°
Turn 90°400
Turn 90°
Turn 90°29
Turn 90°
Turn 90°
Cylinder head x Timing chain cover2121015
Camshaft bearing cap x Cylinder head1616012
Camshaft timing gear x Camshaft7475054
Chain tensioner x Cylinder head2121015
Water bypass outlet x Cylinder head2121015
Heater pipe x Timing chain cover2121015
Heater pipe x Cylinder head2020014
Exhaust manifold x Cylinder head3940029
Heat insulator x Exhaust manifold1919514
Front exhaust pipe x Exhaust manifold6363046
No. 1 support bracket x Transmission2424017
No. 1 support bracket clamp bolt19.519514
Front exhaust pipe x Rear TWC4647034
No. 2 water bypass pipe x Cylinder head2020014
No. 2 water bypass pipe x No. 1 engine hanger2020014
Fuel inlet hose x Fuel filter2930022
Intake manifold stay x Air intake chamber3636026
Intake manifold stay x Cylinder block3636026
Oil dipstick guide x Intake manifold2020014
Oil dipstick guide x No. 1 oil pan2020014
PS reservoir tank x Air intake chamber2020014
Oil jet x Cylinder block2020014
Vibration damper x Cylinder block2020014
Chain tensioner slipper x Cylinder block6970051
Timing chain cover x Cylinder block2121015
Drive belt idler pulley x Timing chain cover4344032
Crankshaft pulley x Crankshaft4124,200304
Transmission housing x No. 1 oil pan7273053
Oil level sensor x No. 1 oil pan5.45548 in.·lbf
Water pump x Cylinder block2121015
Radiator pipe x No. 1 oil pan2121015
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SS−8
−
SERVICE SPECIFICATIONS ENGINE MECHANICAL
1996 LAND CRUISER (RM451U)
A/C compressor bracket x No. 1 oil pan
3737527
A/C compressor bracket x Cylinder block3737527
A/C compressor x A/C compressor bracket2525018
Oil check valve x Cylinder block2525018
Main bearing cap x Cylinder block
1st
2nd74
Turn 90°750
Turn 90°54
Turn 90°
Connecting rod cap x Connecting rod 1st
2nd48
Turn 90°490
Turn 90°35
Turn 90°
Rear oil seal retainer x Cylinder block2121015
Oil cooler cover x Cylinder block2121015
LH engine mounting bracket x Cylinder block6970051
LH insulator x LH engine mounting bracket7273043
RH engine mounting bracket x Cylinder brock6970051
RH insulator x RH engine mounting bracket7273043
PS pump x Cylinder block3637027
Knock sensor x Cylinder block4445033
Oil filter union x Cylinder block4445033
Drive plate x Crankshaft1001,00074
Transmission x Cylinder block7273053
Transmission x No. 1 oil pan7273053
Torque converter clutch x Drive plate5555041
A/T oil cooler pipe x Union (Transmission)3435025
Starter x Transmission3940029
Frame crossmember x Frame6162045
Frame crossmember x Engine rear mounting insulator7475054
Engine front mounting insulator x Frame7475054
Transfer shift lever x Transmission1818513
Transmission shift lever assembly x Body5.45548 in.·lbf
Transmission control rod x Control shaft lever131309
Front propeller shaft x Front dif ferential7475054
Front propeller shaft x Transfer7475054
Rear propeller shaft x Rear differential8890065
Rear propeller shaft x Transfer8890065
Stabillizer bar bracket mounting bolt1818513
Stabillizer bar x Axle carrier2526019
PS pressure hose x PS pump5657542
Rear TWC x Center pipe4040029
Center pipe x Tailpipe4040029
Heated oxygen sensor (Bank 1 sensor 1) x Front exhaust pipe2020014
Heated oxygen sensor (Bank 1 sensor 2) x Center pipe2020014
No. 2 support bracket x Frame18.518513
No. 3 support bracket x Frame18.518513
No. 4 support bracket x Frame18.518513
Exhaust pipe damper x Tailpipe19.519514
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SS1EX−04
SS−16
−
SERVICE SPECIFICATIONS LUBRICATION
1996 LAND CRUISER (RM451U)
TORQUE SPECIFICATION
Part tightenedN·mkgf·cmft·lbf
Oil pan x Drain plug2525018
Oil pump x Relief valve plug4950036
Drive belt idler pulley x Oil pump4344032
Oil strainer x No. 1 oil pan2020014
Baffle plate x No. 1 oil pan9.09078 in.·lbf
No. 1 oil pan x Cylinder block 14 mm head bolt
12 mm head bolt44
20440
20032
14
No. 1 oil pan x Oil pump (Timing chain cover)2020014
No. 2 oil pan x No. 1 oil pan Bolt
Nut7.8
8.880
9069 in.·lbf
78 in.·lbf
No. 1 oil pan x Transmission housing7273053
Oil level sensor x No. 1 oil pan5.45548 in.·lbf
Water pump x Cylinder block2121015
Radiator pipe x No. 1 oil pan2121015
A/C compressor bracket x No. 1 oil pan3737527
A/C compressor bracket x Cylinder block3737527
A/C compressor x A/C compressor bracket2525018
Oil cooler cover x Relief valve plug3737527
Oil cooler x Oil cooler cover1717012
Oil cooler cover x Cylinder block2121015
No. 1 exhaust manifold x Cylinder head3940029
No. 1 exhaust manifold x Heat insulator1919514
Front exhaust pipe x Exhaust manifold6363046
No. 1 support bracket x Transmission housing2424017
Front exhaust pipe x No. 1 support bracket Clamp bolt19.519514
Front exhaust pipe x Rear TWC4647034
Oil check valve x Cylinder block2525018
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SS1F3−04
SS−22
−
SERVICE SPECIFICATIONS CHARGING
1996 LAND CRUISER (RM451U)
TORQUE SPECIFICATION
Part tightenedN·mkgf·cmft·lbf
Bearing retainer x Drive end frame2.62723 in.·lbf
Rectifier end frame x Drive end frame4.54640 in.·lbf
Generator pulley x Rotor11 01,12581
Rectifier x Rectifier holder2.93025 in.·lbf
Rear end cover x Rectifier holder4.44539 in.·lbf
Rectifier plate x Rectifier holder3.83934 in.·lbf
Terminal insulator x Rectifier holder4.14236 in.·lbf
Drive belt adjusting bar x Timing chain cover2121015
Generator x Generator bracket5960043
Drive belt adjusting bar x Generator2121015
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