1996 Toyota Land Cruiser Repair Manual v111

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Text of 1996 Toyota Land Cruiser Repair Manual v111

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Version 1.00 -original version released 12/21/2010 Version 1.11 -released 03/16/2011 -added cover page -added 'Starter' section

Brought to you by BirfMark Version 1.11 - 03/16/2010

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IN1INTRODUCTION HOW TO USE THIS MANUAL

HOW TO USE THIS MANUALGENERAL INFORMATIONIN00U36

1. INDEX An INDEX is provided on the first page of each section to guide you to the item to be repaired. To assist you in finding your way through the manual, the section title and major heading are given at the top of every page. 2. PRECAUTION At the beginning of each section, a PRECAUTION is given that pertains to all repair operations contained in that section. Read these precautions before starting any repair task. 3. TROUBLESHOOTING TROUBLESHOOTING tables are included for each system to help you diagnose the problem and find the cause. The fundamentals of how to proceed with troubleshooting are described on page IN18. Be sure to read this before performing troubleshooting. 4. PREPARATION Preparation lists the SST (Special Service Tools), recommended tools, equipment, lubricant and SSM (Special Service Materials) which should be prepared before beginning the operation and explains the purpose of each one. 5. REPAIR PROCEDURES Most repair operations begin with an overview illustration. It identifies the components and shows how the parts fit together. Example:Filler Cap Float Reservoir z Grommet Slotted Spring Pin15 (155, 11) 12 (120, 9)

Clevis Pin z Gasket Boot

Clip

Clevis Snap Ring Washer Piston Cylinder Push Rod Lock Nut

Nm (kgfcm, ftlbf) : Specified torque z Nonreusable part

N17080

1996 LAND CRUISER (RM451U)

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Author :

Date :

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IN2INTRODUCTION HOW TO USE THIS MANUAL

The procedures are presented in a stepbystep format: S The illustration shows what to do and where to do it. S The task heading tells what to do. S The detailed text tells how to perform the task and gives other information such as specifications and warnings. Example:Task heading : what to do 21. CHECK PISTON STROKE OF OVERDRIVE BRAKE (a) Place SST and a dial indicator onto the overdrive brake piston as shown in the illustration. SST 0935030020 (0935006120) Illustration: what to do and where Set part No. Detailed text : Component part No. how to do task

(b) Measure the stroke applying and releasing the compressed air (392 785 kPa, 4 8 kgf/cm 2 or 57 114 psi) as shown in the illustration. Piston stroke: 1.40 1.70 mm (0.0551 0.0669 in.) Specification

This format provides the experienced technician with a FAST TRACK to the information needed. The upper case task heading can be read at a glance when necessary, and the text below it provides detailed information. Important specifications and warnings always stand out in bold type. 6. REFERENCES References have been kept to a minimum. However, when they are required you are given the page to refer to. 7. SPECIFICATIONS Specifications are presented in bold type throughout the text where needed. You never have to leave the procedure to look up your specifications. They are also found in Service Specifications section for quick reference. 8. CAUTIONS, NOTICES, HINTS: S CAUTIONS are presented in bold type, and indicate there is a possibility of injury to you or other people. S NOTICES are also presented in bold type, and indicate the possibility of damage to the components being repaired. S HINTS are separated from the text but do not appear in bold. They provide additional information to help you perform the repair efficiently. 9. SI UNIT The UNITS given in this manual are primarily expressed according to the SI UNIT (International System of Unit), and alternately expressed in the metric system and in the English System.Example:

Torque: 30 Nm (310 kgfcm, 22 ftlbf)

1996 LAND CRUISER (RM451U)

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IN2INTRODUCTION HOW TO USE THIS MANUAL

The procedures are presented in a stepbystep format: S The illustration shows what to do and where to do it. S The task heading tells what to do. S The detailed text tells how to perform the task and gives other information such as specifications and warnings. Example:Task heading : what to do 21. CHECK PISTON STROKE OF OVERDRIVE BRAKE (a) Place SST and a dial indicator onto the overdrive brake piston as shown in the illustration. SST 0935030020 (0935006120) Illustration: what to do and where Set part No. Detailed text : Component part No. how to do task

(b) Measure the stroke applying and releasing the compressed air (392 785 kPa, 4 8 kgf/cm 2 or 57 114 psi) as shown in the illustration. Piston stroke: 1.40 1.70 mm (0.0551 0.0669 in.) Specification

This format provides the experienced technician with a FAST TRACK to the information needed. The upper case task heading can be read at a glance when necessary, and the text below it provides detailed information. Important specifications and warnings always stand out in bold type. 6. REFERENCES References have been kept to a minimum. However, when they are required you are given the page to refer to. 7. SPECIFICATIONS Specifications are presented in bold type throughout the text where needed. You never have to leave the procedure to look up your specifications. They are also found in Service Specifications section for quick reference. 8. CAUTIONS, NOTICES, HINTS: S CAUTIONS are presented in bold type, and indicate there is a possibility of injury to you or other people. S NOTICES are also presented in bold type, and indicate the possibility of damage to the components being repaired. S HINTS are separated from the text but do not appear in bold. They provide additional information to help you perform the repair efficiently. 9. SI UNIT The UNITS given in this manual are primarily expressed according to the SI UNIT (International System of Unit), and alternately expressed in the metric system and in the English System.Example:

Torque: 30 Nm (310 kgfcm, 22 ftlbf)

1996 LAND CRUISER (RM451U)

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IN3INTRODUCTION IDENTIFICATION INFORMATION

IDENTIFICATION INFORMATIONVEHICLE IDENTIFICATION AND ENGINE SERIAL NUMBER

IN04P14

A

1. VEHICLE IDENTIFICATION NUMBER The vehicle identification number is stamped on the vehicle identification number plate and the certification label, as shown in the illustration. A: Vehicle Identification Number Plate B: Certification LabelB

Z04707

2. ENGINE SERIAL NUMBER The engine serial number is stamped on the engine block, as shown in the illustration.

P03780

1996 LAND CRUISER (RM451U)

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IN4INTRODUCTION REPAIR INSTRUCTIONS

REPAIR INSTRUCTIONSGENERAL INFORMATION

IN0CO12

BASIC REPAIR HINT (a) Use fender, seat and floor covers to keep the vehicle clean and prevent damage. (b) During disassembly, keep parts in the appropriate order to facilitate reassembly.

(c)

FI1066

(d) (e)

Installation and removal of battery terminal: (1) Before performing electrical work, disconnect the negative () terminal cable from the battery. (2) If it is necessary to disconnect the battery for inspection or repair, first disconnect the negative () terminal cable. (3) When disconnecting the terminal cable, to prevent damage to battery terminal, loosen the cable nut and raise the cable straight up without twisting or prying it. (4) Clean the battery terminals and cable ends with a clean shop rag. Do not scrape them with a file or other abrasive objects. (5) Install the cable ends to the battery terminals after loosening the nut, and tighten the nut after installation. Do not use a hammer to tap the cable ends onto the terminals. (6) Be sure the cover for the positive (+) terminal is properly in place. Check hose and wiring connectors to make sure that they are connected securely and correctly. Nonreusable parts (1) Always replace cotter pins, gaskets, Orings, oil seals, etc. with new ones. (2) Nonreusable parts are indicated in the component illustrations by the z symbol.

(f)

Seal Lock AdhesiveZ11554

Precoated parts Precoated parts are bolts, nuts, etc. that are coated with a seal lock adhesive at the factory. (1) If a precoated part is retightened, loosened or caused to move in any way, it must be recoated with the specified adhesive. (2) When reusing precoated parts, clean off the old adhesive and dry with compressed air. Then apply the specified seal lock adhesive to the bolt, nut or threads.Author : Date : 4

1996 LAND CRUISER (RM451U)

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IN5INTRODUCTION REPAIR INSTRUCTIONS

(g) (h) (i)

Precoated parts are indicated in the component illustrations by the L symbol. When necessary, use a sealer on gaskets to prevent leaks. Carefully observe all specifications for bolt tightening torques. Always use a torque wrench. Use of special service tools (SST) and special service materials (SSM) may be required, depending on the nature of the repair. Be sure to use SST and SSM where specified and follow the proper work procedure. A list of SST and SSM can be found in Preparation section in this manual.

(3)

Medium Current Fuse and High Current Fuse Equal Amperage Rating

(j)

When replacing fuses, be sure the new fuse has the correc

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