1. Manuals
  2. Brands
  3. Toyota Manuals
  4. Automobile
  5. 1996 LAND CRUISER
  6. User manual

Toyota 1996 LAND CRUISER User Manual

Hide thumbs
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
101
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
117
118
119
120
121
122
123
124
125
126
127
128
129
130
131
132
133
134
135
136
137
138
139
140
141
142
143
144
145
146
147
148
149
150
151
152
153
154
155
156
157
158
159
160
161
162
163
164
165
166
167
168
169
170
171
172
173
174
175
176
177
178
179
180
181
182
183
184
185
186
187
188
189
190
191
192
193
194
195
196
197
198
199
200
201
202
203
204
205
206
207
208
209
210
211
212
213
214
215
216
217
218
219
220
221
222
223
224
225
226
227
228
229
230
231
232
233
234
235
236
237
238
239
240
241
242
243
244
245
246
247
248
249
250
251
252
253
254
255
256
257
258
259
260
261
262
263
264
265
266
267
268
269
270
271
272
273
274
275
276
277
278
279
280
281
282
283
284
285
286
287
288
289
290
291
292
293
294
295
296
297
298
299
300
301
302
303
304
305
306
307
308
309
310
311
312
313
314
315
316
317
318
319
320
321
322
323
324
325
326
327
328
329
330
331
332
333
334
335
336
337
338
339
340
341
342
343
344
345
346
347
348
349
350
351
352
353
354
355
356
357
358
359
360
361
362
363
364
365
366
367
368
369
370
371
372
373
374
375
376
377
378
379
380
381
382
383
384
385
386
387
388
389
390
391
392
393
394
395
396
397
398
399
400
401
402
403
404
405
406
407
408
409
410
411
412
413
414
415
416
417
418
419
420
421
422
423
424
425
426
427
428
429
430
431
432
433
434
435
436
437
438
439
440
441
442
443
444
445
446
447
448
449
450
451
452
453
454
455
456
457
458
459
460
461
462
463
464
465
466
467
468
469
470
471
472
473
474
475
476
477
478
479
480
481
482
483
484
485
486
487
488
489
490
491
492
493
494
495
496
497
498
499
500
501
502
503
504
505
506
507
508
509
510
511
512
513
514
515
516
517
518
519
520
521
522
523
524
525
526
527
528
529
530
531
532
533
534
535
536
537
538
539
540
541
542
543
544
545
546
547
548
549
550
551
552
553
554
555
556
557
558
559
560
561
562
563
564
565
566
567
568
569
570
571
572
573
574
575
576
577
578
579
580
581
582
583
584
585
586
587
588
589
590
591
592
593
594
595
596
597
598
599
600
601
602
603
604
605
606
607
608
609
610
611
612
613
614
615
616
617
618
619
620
621
622
623
624
625
626
627
628
629
630
631
632
633
634
635
636
637
638
639
640
641
642
643
644
645
646
647
648
649
650
651
652
653
654
655
656
657
658
659
660
661
662
663
664
665
666
667
668
669
670
671
672
673
674
675
676
677
678
679
680
681
682
683
684
685
686
687
688
689
690
691
692
693
694
695
696
697
698
699
700
701
702
703
704
705
706
707
708
709
710
711
712
713
714
715
716
717
718
719
720
721
722
723
724
725
726
727
728
729
730
731
732
733
734
735
736
737
738
739
740
741
742
743
744
745
746
747
748
749
750
751
752
753
754
755
756
757
758
759
760
761
762
763
764
765
766
767
768
769
770
771
772
773
774
775
776
777
778
779
780
781
782
783
784
785
786
787
788
789
790
791
792
793
794
795
796
797
798
799
800
801
802
803
804
805
806
807
808
809
810
811
812
813
814
815
816
817
818
819
820
821
822
823
824
825
826
827
828
829
830
831
832
833
834
835
836
837
838
839
840
841
842
843
844
845
846
847
848
849
850
851
852
853
854
855
856
857
858
859
860
861
862
863
864
865
866
867
868
869
870
871
872
873
874
875
876
877
878
879
880
881
882
883
884
885
886
887
888
889
890
891
892
893
894
895
896
897
898
899
900
901
902
903
904
905
906
907
908
909
910
911
912
913
914
915
916
917
918
919
920
921
922
923
924
925
926
927
928
929
930
931
932
933
934
935
936
937
938
939
940
941
942
943
944
945
946
947
948
949
950
951
952
953
954
955
956
957
958
959
960
961
962
963
964
965
966
967
968
969
970
971
972
973
974
975
976
977
978
979
980
981
982
983
984
985
986
987
988
989
990
Table of Contents

Advertisement

Quick Links

HOW TO USE THIS MANUAL

GENERAL INFORMATION

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 IN−18.
Be sure to read this before performing troubleshooting.
4.
PREPARATION
Preparation lists the SST (Special Service Tools), recommended tools, equipment, lubricant and SSM (Spe-
cial 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:
Slotted Spring Pin
15 (155, 11)
Cylinder
N·m (kgf·cm, ft·lbf)
: Specified torque
z Non−reusable part
1996 LAND CRUISER (RM451U)
Brought to you by BirfMark
INTRODUCTION
−
HOW TO USE THIS MANUAL
Filler Cap
Float
Reservoir
z Grommet
12 (120, 9)
Piston
Brought to you by BirfMark
Version 1.00 - 12/21/2010
Clevis Pin
z Gasket
Boot
Snap Ring
Washer
Push Rod
Author :
Date :
IN−1
IN00U−36
Clip
Clevis
Lock Nut
N17080
1

Advertisement

Table of Contents
loading

Related Manuals for Toyota 1996 LAND CRUISER

Summary of Contents for Toyota 1996 LAND CRUISER

  • Page 1: How To Use This Manual

    Clevis 15 (155, 11) Snap Ring Washer Lock Nut Push Rod Piston Cylinder N·m (kgf·cm, ft·lbf) : Specified torque z Non−reusable part N17080 1996 LAND CRUISER (RM451U) Author : Date : Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 2 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 N·m (310 kgf·cm, 22 ft·lbf) 1996 LAND CRUISER (RM451U) Author : Date : Brought to you by BirfMark...
  • Page 3 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 N·m (310 kgf·cm, 22 ft·lbf) 1996 LAND CRUISER (RM451U) Author : Date : Brought to you by BirfMark...

  • Page 4: Identification Information

    B: Certification Label Z04707 ENGINE SERIAL NUMBER The engine serial number is stamped on the engine block, as shown in the illustration. P03780 1996 LAND CRUISER (RM451U) Author : Date : Brought to you by BirfMark Version 1.00 - 12/21/2010...

  • Page 5: Repair Instructions

    Then apply Seal Lock Adhesive the specified seal lock adhesive to the bolt, nut or Z11554 threads. 1996 LAND CRUISER (RM451U) Author : Date : Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 6 BE1367 Illustration Symbol Part Name Abbreviation FUSE FUSE MEDIUM CURRENT FUSE M−FUSE HIGH CURRENT FUSE H−FUSE FUSIBLE LINK CIRCUIT BREAKER V00076 1996 LAND CRUISER (RM451U) Author : Date : Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 7 Never use an impact wrench to remove or install IN0252 temperature switches or temperature sensors. 1996 LAND CRUISER (RM451U) Author : Date : Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 8 IN0002 temperatures immediately after the vehicle has been run- ning, measurement should be made when the engine has cooled down. 1996 LAND CRUISER (RM451U) Author : Date : Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 9 VEHICLE LIFT AND SUPPORT LOCATIONS Front JACK POSITION Front ........Under front differential Rear ......... Under rear differential SCREW TYPE JACK POSITION SUPPORT POSITION Safety stand ................Z00796 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...

  • Page 10: For All Of Vehicles

    To avoid erasing the memory of each memory sys- tem, never use a back−up power supply from anoth- er battery. 1996 LAND CRUISER (RM451U) Author : Date : Brought to you by BirfMark...
  • Page 11 Refer to SR−19 of this manual concerning correct steer- ing wheel installation. 1996 LAND CRUISER (RM451U) Author : Date : Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 12 SST before disposal (See page RS−11). Perform the operation in a safe place away from electrical noise. CORRECT WRONG Example: Z13953 Example: Z13950 1996 LAND CRUISER (RM451U) Author : Date : Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 13 SST before disposal (See page RS−25). Perform the operation in a safe place away from electrical noise. Example: CORRECT WRONG Z13952 Example: Z13951 1996 LAND CRUISER (RM451U) Author : Date : Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 14 If the SRS wire harness be- comes disconnected or the connector becomes broken due to an accident, etc., repair or replace it as shown on page RS−37. 1996 LAND CRUISER (RM451U) Author : Date : Brought to you by BirfMark...
  • Page 15 Use one of the methods shown below to tow the vehicle. If the vehicle has trouble in the chassis and drive train, use method 1 (flat bed truck). V08127 1996 LAND CRUISER (RM451U) Author : Date : Brought to you by BirfMark...
  • Page 16 TOYOTA hand−held tester’s operator manual should be read thoroughly. Be sure to route all cables securely when driving with the OBD II scan tool or TOYOTA hand− held tester connected to the vehicle. (i.e. Keep cables away from feet, pedals, steering wheel and shift lever.)
  • Page 17 ID number afterwards, or else a request made to the customer to input the ID number. For the method to input the ID number or cancel the anti−theft system, refer to the Owner’s Manual. 1996 LAND CRUISER (RM451U) Author : Date : Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 18 DI−238 5. Cruise Control System DI−284 FOR USING OBD II SCAN TOOL OR TOYOTA HAND−HELD TESTER Before using the scan tool or tester, the scan tool’s instruction book or tester’s operator manual should be read thoroughly. If the scan tool or tester cannot communicate with ECU controlled systems when you have connected the cable of the scan tool or tester to DLC3, turned the ignition switch ON and operated the scan tool, there is a problem on the vehicle side or tool side.
  • Page 19 (If the problem is not reproduced, perform the confirmation test under the same conditions and in the same environment as when it occurred for the first time.) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 20 After accelerator pedal depressed Engine Stall After accelerator pedal released During A/C operation Shifting from N to D Other Others Data Problem Constant Sometimes ( times per day/month) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 21 No problem Normal code is The problem occurred in a place other symptoms exist displayed than in the diagnostic circuit in the past 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 22 Therefore, check the wire harness and con- nectors (See page IN−28). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 23 Apply slight vibration with a finger to the part of the sensor considered to be the problem cause and check that the mal- function occurs. HINT: Applying strong vibration to relays may result in open relays. V07268 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 24 OTHER: When a malfunction seems to occur when electrical load is excessive. Turn on all electrical loads including the heater blower, head lights, rear window defogger, etc. and check to see if the mal- function occurs. B02389 B02390 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 25 Throttle/ Pedal Position Sensor/Switch D Throttle position sensor ”A” Circuit Malfunction D ECM Throttle/ Pedal Position Sensor/ Switch D Throttle position sensor ”A” Circuit Range / Performance Prob- 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 26 High engine idle speed (Poor idling) 2. ECM power source circuit 1. A/C signal circuit idling) 2. Fuel pump control circuit 1. Compression 2. Fuel pump control circuit 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...

  • Page 27: Circuit Inspection

    O = Orange, W = White, GR = Gray, P = Pink, Y = Yellow, SB = Sky Blue The first letter indicates the basic wire color and the second letter indicates the color of the stripe. V08423 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 28 D Indicates the condition of the connector of ECU during the check. E6 Connector E6 Connector Connector being checked is disconnected. Connector being checked is connected. V08425 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 29 When there is a short circuit between the wire harness and body ground, check thoroughly whether the wire harness is caught in the body or is clamped properly. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 30 Pull Lightly check that the terminals are secured in lock portion. Looseness of Crimping HINT: The terminals should not come out when pulled lightly from the back. IN0381 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 31 1 of connector ”C” → No continuity (open) Therefore, it is found out that there is an open circuit between terminal 1 of connector ”B2” and terminal B04722 1 of connector ”C”. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 32 → No continuity Z17009 Therefore, it is found out that there is a short circuit between terminal 1 of connector ”A” and terminal 1 of connector ”C”. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 33 Disconnect the ECU connector, check the ground ECU Side terminals on the ECU side and the wire harness side for bend and check the contact pressure. Ground W/H Side Ground IN0384 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 34 Cornering Force Center Of Gravity Channel COMB. Combination Coupe Combustion Pressure Sensor Central Processing Unit Child Restraint System Center Check Valve Control Valve 1996 LAND CRUISER (RM451U) Author : Date : Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 35 Fusible Link Fuel Pump Fuel Pressure Up Front Front−Engine Rear−Wheel−Drive Flywheel FW/D Flywheel Damper Front−Wheel−Drive Gasoline Gear Shift Actuator Ground High Altitude Compensator 1996 LAND CRUISER (RM451U) Author : Date : Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 36 Load Sensing Proportioning Valve MAX. Maximum M−FUSE Medium Current Fuse Microphone Malfunction Indicator Lamp MIN. Minimum Multipurpose Multiplex Communication System Manual Transmission (Transaxle) Mount Mounting Neutral 1996 LAND CRUISER (RM451U) Author : Date : Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 37 Supplemental Restraint System Special Service Materials Special Service Tools Standard Cold−Start Fuel Injection Switch System Transaxle TACH Tachometer Throttle Body Electronic Fuel Injection 1996 LAND CRUISER (RM451U) Author : Date : Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 38 Timing Control Valve Top Dead Center TEMP. Temperature TEMS TOYOTA Electronic Modulated Suspension Total Information System For Vehicle Development Transmission TOYOTA Motor Corporation TMMK TOYOTA Motor Manufacturing Kentucky, Inc. TRAC Traction Control System TURBO Turbocharge Underdrive Undersize Vacuum Control Valve VENT Ventilator...
  • Page 39 − TERMS IN0CI−02 GLOSSARY OF SAE AND TOYOTA TERMS This glossary lists all SAE−J1930 terms and abbreviations used in this manual in compliance with SAE rec- ommendations, as well as their TOYOTA equivalents. TOYOTA TERMS SAE TERMS ABBREVIATIONS ( )−−ABBREVIATIONS...
  • Page 40 System Readiness Test − Scan Tool − Throttle Body Throttle Body Single Point Injection Throttle Body Fuel Injection Central Fuel Injection (Ci) Turbocharger Turbocharger Torque Converter Clutch Torque Converter 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 41 Vehicle Speed Sensor Wide Open Throttle Full Throttle WU−OC Warm Up Oxidation Catalytic Converter − WU−TWC Warm Up Three−Way Catalytic Converter − Third Gear − Fourth Gear − 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...

  • Page 42: Air Conditioning System

    BE CAREFUL NOT TO OVERCHARGE SYSTEM WITH REFRIGERANT If refrigerant is overcharged, it causes problems such as insuffi- cient cooling, poor fuel economy, engine overheating etc. 1996 LAND CRUISER (RM451U) Author : Date : 1328 Brought to you by BirfMark...
  • Page 43 Before servicing (including re- moval or installation of parts, inspection or replacement), be sure to read the following item carefully, then follow the correct procedure described in the repair manual. 1996 LAND CRUISER (RM451U) Author : Date : 1329 Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 44 Cool air comes out only at high engine rpm 6. Receiver AC−39 7. Expansion valve AC−47 8. Evaporator AC−45 9. Thermistor AC−60 10.A/C amplifier AC−74 11.Wire harness − 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 45 3. Rear heater switch AC−77 4. Rear blower motor AC−55 5. Rear blower resistor AC−58 1. Engine coolant volume − No warm air come out 2. Rear heater radiator AC−46 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 46 Normally functioning refrigeration system. Gauge reading: Low pressure side: 0.15 − 0.25 MPa (1.5 − 2.5 kgf/cm High pressure side: 1.37 − 1.57 MPa (14 − 15 kgf/cm I01386 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 47 (3) If indicated pressure value is tinuously near 0 when connected to gauge, S Insufficient cooling performance create the vacuum after inspecting and repairing the location of the leak 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 48 S Refrigerant flow obstructed by fore and after condenser/ drier or gas leakage from expansion valve (5) For gas leakage from expan- expansion valve sion valve, replace expansion valve 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 49 S The low pressure piping hot to Air entered in refrigeration system (2) Evacuate air and charge new touch S Insufficient vacuum purging refrigerant S Bubbles seen in sight glass 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 50 Internal leak in compressor S Valve leaking or broken sliding Repair or replace compressor S Pressure too low on high pres- parts sure side 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 51 20 minutes. Then bring the gas leak de- tector close to the pressure switch and perform the test. Bring the gas leak detector close to the refrigerant lines and perform the test. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 52 Leave the system in this condition for 5 minutes or more and check that there is no gauge indicator. High Pressure Service Valve Vacuum Pump Adapter N13791 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 53 Add evacuate air from refrigeration system (Refer to 4). CAUTION: Use the refrigerant recovery/ recycling machine to recover the refrigerant whenever replacing parts. Gas Leak Detector N13792 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 54 AUTOMATIC TRANSMISSION AUTOMATIC TRANSMISSION SYSTEM AUTOMATIC TRANSMISSION SYSTEM AT0SY-01 PRECAUTION If the vehicle is equipped with a mobile communication system, refer to the precautions in the IN section. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 55 Close both hand valves of manifold gauge set. Disconnect the quick disconnect adapters from the ser- vice valves. INSTALL CAPS TO SERVICE VALVES ON REFRIGER- ANT LINES 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 56 Brought to you by BirfMark AC−14 AIR CONDITIONING − AIR CONDITIONING SYSTEM AC2QB−01 POSITIONING Z04523 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...

  • Page 57: Drive Belt

    ”Used belt” refers to a belt which has been on a running engine for 5 minutes or more. After installing the drive belt, check that it fits properly in the ribbed grooves. 1996 LAND CRUISER (RM451U) Author : Date : 1342 Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 58 REMOVAL LOOSEN IDLE PULLEY LOCK NUT Torque: 39 N·m (400 kgf·cm, 29 ft·lbf) REMOVE COMPRESSOR DRIVE BELT Loosen the adjusting bolt and remove the drive belt. N16451 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 59 Brought to you by BirfMark AC−17 AIR CONDITIONING − DRIVE BELT AC2QI−01 INSTALLATION Installation is in the reverse order of removal (See page AC−16). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...

  • Page 60: Manifold Gauge Set

    Push the quick disconnect adapter onto the service valve, then Sleeve slide the sleeve of the quick disconnect adapter downward to lock it. N04392 1996 LAND CRUISER (RM451U) Author : Date : 1345 Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 61 Slide the sleeve of the quick disconnect adapter upward to un- lock the adapter and remove it from the service valve. INSTALL CAPS TO SERVICE VALVES ON REFRIGER- N06553 ANT LINE 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...

  • Page 62: Refrigerant Line

    AC2QM−01 ON−VEHICLE INSPECTION INSPECTION HOSE AND TUBE CONNECTIONS FOR LOOSENESS INSPECT HOSES AND TUBES FOR LEAKAGE Using a gas leak detector, check for leakage of refrigerant. 1996 LAND CRUISER (RM451U) Author : Date : 1347 Brought to you by BirfMark...
  • Page 63 10 (100, 7) 10 (100, 7) Suction Hose Receiver Discharge Hose 5.4 (55, 48 in.·lbf) Condenser 10 (100, 7) N·m (kgf·cm, ft·lbf) : Specified torque z Non−reusable part Z17947 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 64 INSPECT FOR LEAKAGE OF REFRIGERANT Using a gas leak detector, check for leakage of refrigerant. If there is leakage, check the tightening torque at the joints. INSPECT AIR CONDITIONING OPERATION 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...

  • Page 65: Cooling Unit

    Brought to you by BirfMark AC−23 AIR CONDITIONING − COOLING UNIT COOLING UNIT AC3JL−01 COMPONENTS 1996 LAND CRUISER (RM451U) Author : Date : 1350 Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 66 Glove compratment door (See page BO−76) Glove compratment door reinforcement (See page BO−76) REMOVE COOLING UNIT Disconnect the connectors. Remove the 4 screws, 2 nuts and cooling unit. N14293 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 67 Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf) HINT: At the time of reassembly, lubricate 4 new O−rings with com- pressor oil and install the tubes. Expansion Valve N06174 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 68 Brought to you by BirfMark AC−26 AIR CONDITIONING − COOLING UNIT AC2QQ−01 REASSEMBLY Reassembly is in the reverse order of disassembly (See page AC−25). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 69 Brought to you by BirfMark AC−27 AIR CONDITIONING − COOLING UNIT AC2QR−01 INSTALLATION Installation is in the reverse order of removal (See page AC−24). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...

  • Page 70: Heater Unit

    (See page BO−76) Upper 45° 10° Marking 45 ± 10° Z17943 REMOVE HEATER UNIT Remove the 3 screws and defroster nozzle. N06494 1996 LAND CRUISER (RM451U) Author : Date : 1355 Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 71 Brought to you by BirfMark AC−29 AIR CONDITIONING − HEATER UNIT Remove the 2 nuts and a screw, then remove heater unit. N06495 1996 LAND CRUISER (RM451U) Author : Date : 1356 Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 72 Brought to you by BirfMark AC−30 AIR CONDITIONING − HEATER UNIT AC2QV−01 INSTALLATION Installation is in the reverse order of removal (See page AC−28). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...

  • Page 73: Blower Unit

    MENT (See page BO−76) REMOVE COOLING UNIT (See page AC−24) REMOVE BLOWER UNIT Disconnect the connectors. Remove the bolt and 2 nuts, then remove the blower unit. 1996 LAND CRUISER (RM451U) Author : Date : 1358 Brought to you by BirfMark...
  • Page 74 Brought to you by BirfMark AC−32 AIR CONDITIONING − BLOWER UNIT AC2R4−01 INSTALLATION Installation is in the reverse order of removal (See page AC−31). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...

  • Page 75: Compressor And Magnetic

    (−) lead to the body ground. Check that the magnetic clutch is energized. If operation is not as specified, replace the magnetic clutch. N06158 1996 LAND CRUISER (RM451U) Author : Date : 1360 Brought to you by BirfMark...
  • Page 76 Drive Belt N·m (kgf·cm, ft·lbf) : Specified torque 37 (375, 27) z Non−reusable part Z17948 Rotor Pressure Plate 13.2 (135, 9) Shim Compressor Startor Snap Ring Z17949 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 77 Torque: 13.2 N·m (135 kgf·cm, 9 ft·lbf) 07112−76060 AC0943 Install a SST on the pressure plate. 07112−66040 AC0944 Using SST and a socket wrench, remove the pressure plate. 07112−76060 AC0945 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 78 NOTICE: Be careful not to damage the pulley when tapping on the ro- tor. AC1743 REMOVE STATOR Disconnect the stator lead wire from the compressor housing. AC1744 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 79 07114−84020 AC0950 NOTICE: The snap ring should be installed so that its beveled side R−Shape faces up. Snap Ring Stator Compressor N20012 Remove the stator. Stator AC0951 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 80 If the clearance is not within the standard clearance, adjust the clearance using shims to obtain the standard clearance. Shim Thickness: 0.1 mm (0.004 in.) 0.3 mm (0.012 in.) 0.5 mm (0.020 in.) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 81 AC2RB−01 ON−VEHICLE INSPECTION INSPECT FITTINGS FOR LEAKAGE Using a gas leak detector, check for leakage. If there is leakage, check the tightening toque at the joints. 1996 LAND CRUISER (RM451U) Author : Date : 1366 Brought to you by BirfMark...
  • Page 82 Remove the holder bolt and pull the receiver down ward. HINT: If receiver was replaced, add compressor oil to compressor. Add 10 cc (0.35 fl.oz.) Compressor oil: ND−OIL 8 or equivalent N13975 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 83 Brought to you by BirfMark AC−41 AIR CONDITIONING − RECEIVER AC2RD−01 INSTALLATION Installation is in the reverse order of removal (See page AC−40). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 84 Be careful not to damage the fins. If the fins are bent, straighten them with a screwdriver or pliers. INSPECT CONDENSER AND FITTINGS FOR LEAKAGE Repair as necessary. 1996 LAND CRUISER (RM451U) Author : Date : 1369 Brought to you by BirfMark...
  • Page 85 Pull out the condenser between the radiator and the body. HINT: If condenser was replaced, add compressor oil to compressor. Add 40 cc (1.4 fl.oz.) Compressor oil: Condenser ND−OIL 8 or equivalent AC2674 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 86 Brought to you by BirfMark AC−44 AIR CONDITIONING − CONDENSER AC2RF−01 INSTALLATION Installation is in the reverse order of removal (See page AC−43). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 87 NOTICE: Never use water to clean the evaporator. CHECK FITTINGS FOR CRACKS OR SCRATCHES Repair as necessary. REINSTALL EVAPORATOR (See page AC−26) 1996 LAND CRUISER (RM451U) Author : Date : 1372 Brought to you by BirfMark Version 1.00 - 12/21/2010...

  • Page 88: Heater Radiator

    Remove the screws and plates. Pull the heater radiator out. INSPECT FINS FOR BLOCKAGE If the fins are clogged, clean them with compressed air. INSTALL HEATER RADIATOR 1996 LAND CRUISER (RM451U) Author : Date : 1373 Brought to you by BirfMark...

  • Page 89: Expansion Valve

    HINT: When the low pressure drops to 0 kPa (0 kgf/cm , 0 psi), feel the receiver’s IN and OUT sides for zero temper- ature difference. 1996 LAND CRUISER (RM451U) Author : Date : 1374 Brought to you by BirfMark...

  • Page 90: Water Valve

    REMOVE WIRE HARNESS PROTECTOR REMOVE WATER VALVE Water Hose Remove the 2 bolts and water valve. Hose ”A” Hose ”B” Upper Upper 45° Marking Z19353 1996 LAND CRUISER (RM451U) Author : Date : 1375 Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 91 Blower speed control switch on. Temperature control switch to ”COOL” position. Set the water valve to ”COOL” position, install the control cable and lock the clamp. N14296 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 92 Brought to you by BirfMark AC−50 AIR CONDITIONING − WATER VALVE AC2RV−01 INSTALLATION Installation is in the reverse order of removal (See page AC−48). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...

  • Page 93: Front Blower Motor

    Remove the 2 screws, then remove the lower cover while pushing the locking protrsion, as shown. Disconnect the connector from the blower motor. Remove the 3 screws and blower motor. 1996 LAND CRUISER (RM451U) Author : Date : 1378 Brought to you by BirfMark...
  • Page 94 (−) lead to terminal 1, then check that the motor op- eration is smooth. If operation is not as specified, replace the blower motor. AC2227 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 95 Brought to you by BirfMark AC−53 AIR CONDITIONING − FRONT BLOWER MOTOR AC2RZ−01 INSTALLATION Installation is in the reverse order of removal (See page AC−51). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...

  • Page 96: Rear Blower Motor

    N14324 Remove the bolt and 7 screws, then remove the upper cover with the blower motor. Remove the 3 screws and the blower motor. N06504 1996 LAND CRUISER (RM451U) Author : Date : 1381 Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 97 Connect the positive (+) lead from the battery to terminal 1 and the negative (−) lead to terminal 2, then check that the motor op- erations smoothly. If operation is not as specified, replace the motor. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 98 Brought to you by BirfMark AC−56 AIR CONDITIONING − REAR BLOWER MOTOR AC2S2−01 INSTALLATION Installation is in the reverse order of removal (See page AC−54). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...

  • Page 99: Blower Resistor

    Measure resistance between terminals 1 and 4. Standard resistance: 1.8 − 2.2 Ω If resistance is not as specified, replace the blower resistor. REINSTALL BLOWER RESISTOR N09039 1996 LAND CRUISER (RM451U) Author : Date : 1384 Brought to you by BirfMark...
  • Page 100 Constant Continuity A2 − A3 − B2 If continuity is not as specified, replace the blower resistor. REINSTALL REAR BLOWER RESISTOR Z09802 1996 LAND CRUISER (RM451U) Author : Date : 1385 Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 101 Measure the resistance between terminals. Standard resistance: 1,500 Ω at 25 °C (77 °F) N14295 If resistance is not as specified, replace the sensor. 1996 LAND CRUISER (RM451U) Author : Date : 1386 Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 102 Compare the 2 readings on the chart. (Ω) 5,000 If resistance is not as specified, replace the thermistor. 4,500 4,000 REINSTALL THERMISTOR 3,500 3,000 2,500 2,000 1,500 1,000 25(°C) 77 (°F) Z04352 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...

  • Page 103: Pressure Switch

    (2.0 kgf·cm , 28 psi) (32.0 kgf·cm , 455 psi) OFF (No Continuity) OFF (No Continuity) CONNECT CONNECTOR TO PRESSURE SWITCH Z13470 1996 LAND CRUISER (RM451U) Author : Date : 1388 Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 104 HINT: Lock the switch mount on the tube with an open end wrench, being careful not to deform the tube, and remove the switch. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 105 Brought to you by BirfMark AC−63 AIR CONDITIONING − PRESSURE SWITCH AC2SD−01 INSTALLATION Installation is in the reverse order of removal (See page AC−62). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 106 2 − 4 Apply B+ between 4 − 5 Continuity terminals 3 and 5. Z19533 If continuity is not as specified, replace the relay. 1996 LAND CRUISER (RM451U) Author : Date : 1391 Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 107 1 − 3 Apply B+ between 1 − 4 Continuity terminals 2 and 6. Z09804 If continuity is not as specified, replace the relay. 1996 LAND CRUISER (RM451U) Author : Date : 1392 Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 108 Continuity Apply B+ between 2 − 4 Continuity terminals 1 and 3. If continuity is not as specified, replace the relay. Z09507 1996 LAND CRUISER (RM451U) Author : Date : 1393 Brought to you by BirfMark Version 1.00 - 12/21/2010...

  • Page 109: Engine Coolant

    Check the continuity betweeen terminals of the switch, as shown in the chart below. If continuity is not as specified, replace the switch. N06549 108°C (226°F) 103°C (217°F) V02084 1996 LAND CRUISER (RM451U) Author : Date : 1394 Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 110 REMOVE INSTRUMENT CLUSTER FINISH CENTER PANEL WITH A/C CONTROL ASSEMBLY REMOVE A/C CONTROL ASSEMBLY Remove the 3 screws and A/C control assembly from center panel. N14164 1996 LAND CRUISER (RM451U) Author : Date : 1395 Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 111 FRESH or RECIRC indicator light lights up. Next, push in the button again, and check that the indica- tor light goes off and the other indicator light lights up. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 112 Then connect the positive (+) lead from the battery to ter- Connector ”A” minal A−13 and check that the indicator dims. If operation is not as specified, replace the A/C control assem- bly. Connector ”B” AC2723 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 113 TINUITY Switch position Tester connection Specified condition A10 − B16 Continuity A1 − B16 Continuity B9 − B16 Continuity B10 − B16 Continuity B13 − B16 Continuity 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 114 B−3 increases from 0 to approx. 3.0 kΩ when the switch knob is turned from COOL to HOT. If operation is not as specified, replace the A/C control assem- bly. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 115 Brought to you by BirfMark AC−73 AIR CONDITIONING − AIR CONDITIONING CONTROL ASSEMBLY AC2SN−01 INSTALLATION Installation is the revese order of removal (See page AC−68). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...

  • Page 116: Air Conditioning Amplifier

    3 − Ground No voltage less than 2.0 − 32 kgf/cm or more If circuit is not as specified, replace the amplifier. 1996 LAND CRUISER (RM451U) Author : Date : 1401 Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 117 AIR CONDITIONING AMPLIFIER AC2SJ−01 REMOVAL REMOVE GLOVE COMPARTMENT DOOR (See page BO−76) REMOVE A/C AMPLIFIER Disconnect the connector from the amplifier. Remove the screw and the amplifier. N14294 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 118 Brought to you by BirfMark AC−76 AIR CONDITIONING − AIR CONDITIONING AMPLIFIER AC2SK−01 INSTALLATION Installation is in the reverse order of removal See page AC−75). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 119 No Continuity 1 − 2 Continuity Illumination circuit 3 − 6 Continuity If continuity is not as specified, replace the switch. Z15447 1996 LAND CRUISER (RM451U) Author : Date : 1404 Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 120 Shift Lever Position Gear Position Parking Reverse Neutral Down−shift only in the 2 position and 3rd gear−no up−shift. Down−shift only in the L position and 2nd gear−no up−shift. V07130 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 121 Install the speedometer driven gear. Install the locking plate with the bolt. Torque: 16 N·m (160 kgf·cm, 12 ft·lbf) Q07268 Connect the speedometer cable. 1996 LAND CRUISER (RM451U) Author : Date : Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 122 Brought to you by BirfMark AT−4 AUTOMATIC TRANSMISSION − SPEEDOMETER DRIVEN GEAR Tighten the serrated collar with pliers. 1996 LAND CRUISER (RM451U) Author : Date : Brought to you by BirfMark Version 1.00 - 12/21/2010...

  • Page 123: Vehicle Speed Sensor

    Install the No.2 vehicle speed sensor and torque the bolt. Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf) RECONNECT NO.2 VEHICLE SPEED SENSOR CON- NECTOR 1996 LAND CRUISER (RM451U) Author : Date : Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 124 (See page DI−131) RECONNECT PARK/NEUTRAL POSITION SWITCH CONNECTOR RECONNECT 2 OIL COOLER PIPES (See page AT−17) Adjust the shift lever position. (See page DI−131) 1996 LAND CRUISER (RM451U) Author : Date : Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 125 Be careful as some fluid will come out with the oil strainer. Bolt length: Bolt A: 16 mm (0.63 in.) Bolt B: 20 mm (0.79 in.) Bolt C: 28 mm (1.10 in.) 1996 LAND CRUISER (RM451U) Author : Date : Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 126 At the time of installation, install the body together the check ball body and spring and Align the groove of the manual valve to the pin of the lever. AT1369 1996 LAND CRUISER (RM451U) Author : Date : Brought to you by BirfMark...
  • Page 127 REINSTALL VALVE BODY ASSEMBLY To install, follow the removal procedure in reverse. HINT: After installation, fill ATF and check the fluid level. (See page DI−131) 1996 LAND CRUISER (RM451U) Author : Date : Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 128 Push the lock rod fully forward. Check that the parking lock pawl operates smoothly. Torque: 7.4 N·m (75 kgf·cm, 65 in.·lbf) REINSTALL VALVE BODY (See page AT−7) AT2001 1996 LAND CRUISER (RM451U) Author : Date : Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 129 After installation, fill ATF and check the fluid level (0.031 − 0.059 in.) Q05731 (See page DI−131). Adjust the throttle cable (See page DI−131). 1996 LAND CRUISER (RM451U) Author : Date : Brought to you by BirfMark Version 1.00 - 12/21/2010...

  • Page 130: Shift Lock System

    Shift Lock Solenoid Stop Light Switch − Shift Lock Shift Lock Control ECU Control Switch MAIN Key Interlock Solenoid Stop Light Battery Z16651 1996 LAND CRUISER (RM451U) Author : Date : Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 131 Q07316 Apply the battery positive voltage between terminals. At this time, confirm that solenoid operate. If the operation is not as specified, replace the solenoid. Battery Q07315 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 132 P2 − P R, N, D, 2, L position P2 − P Continuity Q07314 If the continuity is not as specified, replace the switch. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 133 Brought to you by BirfMark AT−15 AUTOMATIC TRANSMISSION − AIR COOLED OIL COOLER AIR COOLED OIL COOLER AT0T8−01 COMPONENTS Oil Cooler Radiator Grille Q07275 1996 LAND CRUISER (RM451U) Author : Date : Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 134 Remove the radiator grille. REMOVE OIL COOLER Loosen the 2 clips and disconnect the 2 hoses. Remove the 8 bolts and oil cooler. Torque: 11 N·m (115 kgf·cm, 8 ft·lbf) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 135 − AIR COOLED OIL COOLER AT0TA−01 INSTALLATION Installation is in the reverse order of removal (See page AT−16). HINT: After installation, check fluid level (See page DI−131). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 136 Oil Filler Pipe z Gasket z O−Ring z Gasket Hole Plug Engine Under Cover Crossmember with Stabilizer Bar Transfer Under Cover z Non−reusable Part Q08463 1996 LAND CRUISER (RM451U) Author : Date : Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 137 Control Link Transfer Shift Lever Cushion Rear Console Box Front Console Box Oil Cooler Pipe Engine Rear Mounting Plug for Hydraulic Test Q08467 1996 LAND CRUISER (RM451U) Author : Date : Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 138 Remove the clip, washer and wave washer, and discon- nect the transfer shift lever link. Remove the nut and washer, and disconnect the trans- mission select lever link. Torque: 13 N·m (130 kgf·cm, 9 ft·lbf) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 139 Remove the 3 bolts and console box. Disconnect the 3 connectors. Remove the 6 screws and transmission shift lever assem- bly. Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 140 At the time of installation, replace the used O−ring with a new one. LOOSEN 2 OIL COOLER PIPE UNION NUTS Torque: 34 N·m (350 kgf·cm, 25 ft·lbf) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 141 Loosen the clamp bolt and disconnect the clamp from the No.1 support bracket. Torque: 19 N·m (195 kgf·cm, 14 ft·lbf) Remove the 2 bolts and No.1 support bracket. Torque: 24 N·m (240 kgf·cm, 17 ft·lbf) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 142 2 oil cooler pipes from the elbows. Remove the 10 bolts and transmission. Torque: 72 N·m (730 kgf·cm, 53 ft·lbf) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 143 Installation is in the reverse order of removal (See page AT−20). HINT: After installation, adjust the shift lever position and throttle cable (See page DI−131). Fill and check fluid level (See page DI−131). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...

  • Page 144: Body Electrical System

    (−) terminal cable is reconnected to the battery. MOBILE COMMUNICATION SYSTEM If the vehicle is equipped with a mobile communication system, refer to precautions in the IN section. 1996 LAND CRUISER (RM451U) Author : Date : 1139 Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 145 3. TAIL Fuse (I/P F/B) − 4. Light Control Switch BE−14 5. Wire Harness − 1. Light Control Switch BE−14 Headlight and Taillight does not light. 2. Wire Harness − 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...

  • Page 146: Interior Light System

    1. GAUGE Fuse (I/P F/B) − 2. Ignition Switch BE−11 Back−Up light does not light up. 3. Park/Neutral Position Switch (A/T) − 4. Bulb − 5. Wire Harness − 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...

  • Page 147: Stop Light System

    1. Meter Circuit BE−32 Tachometer does not operate. 2. Igniter − 3. Wire Harness − 1. Voltmeter Receiver Gauge AT−6 Voltmeter does not operate. 2. Wire Harness − 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...

  • Page 148: Warning Lights

    2. Seat Belt Buckle Switch BE−34 Seat belt warning light does not light up. 3. Seat Belt Warning Relay (I/P F/B) − 4. Meter Circuit BE−32 5. Wire Harness − 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...

  • Page 149: Indicator Lights

    3. Wire Harness − 1. Bulb − 2. Cruise Control ECU − Cruise control indicator light does not light up. 3. Meter Circuit BE−32 4. Wire Harness − 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 150 − (Door lock does not operate.) 5. Sliding Roof Control Switch BE−58 6. Sliding Roof Control Relay BE−58 7. Sliding Roof Motor BE−58 8. Wire Harness − 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 151 2. Power Seat Switch BE−62 3. Wire Harness − 1. Lumber Support Motor BE−62 ”Lumber support operation” does not operate. 2. Lumber Support Switch BE−62 3. Wire Harness − 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...

  • Page 152: Power Source

    Brought to you by BirfMark BE−9 BODY ELECTRICAL − POWER SOURCE POWER SOURCE BE1LU−01 LOCATION 1996 LAND CRUISER (RM451U) Author : Date : 1147 Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 153 Brought to you by BirfMark BE−10 BODY ELECTRICAL − IGNITION SWITCH AND KEY UNLOCK WARNING SWITCH IGNITION SWITCH AND KEY UNLOCK WARNING SWITCH BE1LV−01 LOCATION 1996 LAND CRUISER (RM451U) Author : Date : 1148 Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 154 Continuity If continuity is not as specified, replace the switch. INSPECT DOOR COURTESY SWITCH CONTINUITY (See page BE−21) INSPECT SEAT BELT WARNING RELAY CIRCUIT (See page BE−34) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 155 Brought to you by BirfMark BE−12 BODY ELECTRICAL − HEADLIGHT AND TAILLIGHT SYSTEM HEADLIGHT AND TAILLIGHT SYSTEM BE1LX−01 LOCATION 1996 LAND CRUISER (RM451U) Author : Date : 1150 Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 156 Brought to you by BirfMark BE−13 BODY ELECTRICAL − HEADLIGHT AND TAILLIGHT SYSTEM BE1LY−01 COMPONENTS 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 157 Specified condition Constant 1 − 2 Continuity Apply B+ between 2 − 3 Continuity terminals 1 and 2. If continuity is not as specified, replace the relay. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 158 Connect the negative (−) lead to terminal 5, and check that the test bulb goes out. If operation is not as specified, replace the relay. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 159 If the gauge bubble is outside the acceptable range of the beam angle gauge, adjust it using adjusting screw A. HINT: The beam angle will change about 0°11’ with one mark. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 160 HINT: For adjustment, pull nut C to the rear of the vehicle to free it. Af- ter adjustment, check that the nut C is locked in. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 161 Brought to you by BirfMark BE−18 BODY ELECTRICAL − TURN SIGNAL AND HAZARD WARNING SYSTEM TURN SIGNAL AND HAZARD WARNING SYSTEM BE1M1−01 LOCATION 1996 LAND CRUISER (RM451U) Author : Date : 1156 Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 162 If one of the front or rear turn signal lights has an open circuit, the number of flashes will be more than 140 per minute. BE1843 If operation is not as specified, replace the flasher. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 163 Brought to you by BirfMark BE−20 BODY ELECTRICAL − INTERIOR LIGHT SYSTEM INTERIOR LIGHT SYSTEM BE1M3−01 LOCATION 1996 LAND CRUISER (RM451U) Author : Date : 1158 Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 164 2 and body ground. Turn the room light switch DOOR, and check that there is continuity between terminal 1 and 2. If operation is not as specified, replace the switch. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 165 Brought to you by BirfMark BE−22 BODY ELECTRICAL − BACK−UP LIGHT SYSTEM BACK−UP LIGHT SYSTEM BE1M5−01 LOCATION 1996 LAND CRUISER (RM451U) Author : Date : 1160 Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 166 Brought to you by BirfMark BE−23 BODY ELECTRICAL − BACK−UP LIGHT SYSTEM BE1M6−01 INSPECTION INSPECT PARK/NEUTRAL POSITION SWITCH CONTINUITY (See page AT−6) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 167 Brought to you by BirfMark BE−24 BODY ELECTRICAL − STOP LIGHT SYSTEM STOP LIGHT SYSTEM BE1M7−01 LOCATION 1996 LAND CRUISER (RM451U) Author : Date : 1162 Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 168 Tester connection Specified condition SW pin free 1 − 2 Continuity SW pin pushed in − No continuity If continuity is not as specified, replace the switch. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 169 Brought to you by BirfMark BE−26 BODY ELECTRICAL − WIPER AND WASHER SYSTEM WIPER AND WASHER SYSTEM BE1M9−01 LOCATION 1996 LAND CRUISER (RM451U) Author : Date : 1164 Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 170 After connecting terminal B4 to termianl B18, connect B18 to terminal B16. Then, check that the voltage rises from O volt to battery positive voltage within time as follows. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 171 3 and the negative (−) lead to terminal 6, and check that the meter needle indicates to battery positive voltage. If operation is not as specified, replace the relay. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 172 Operate the motor at low speed and stop the motor opera- tion anywhere except at the stop position by disconnect- ing positive (+) lead from terminal 3. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 173 NOTICE: These tests must be performed quickly (within 20 seconds) to prevent the coil from burning out. If operation is not as specified, replace the motor. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 174 Brought to you by BirfMark BE−31 BODY ELECTRICAL − COMBINATION METER COMBINATION METER BE1MB−01 LOCATION 1996 LAND CRUISER (RM451U) Author : Date : 1169 Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 175 Brought to you by BirfMark BE−32 BODY ELECTRICAL − COMBINATION METER BE1MC−01 CIRCUIT 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 176 Brought to you by BirfMark BE−33 BODY ELECTRICAL − COMBINATION METER 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 177 Compare the tester and tachometer indications. If error is excessive, replace the tachometer. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 178 A − C 126 − 150 B − C *90 − 110 *: Include voltmeter resistance If resistance value is not as specified, replace the fuel receiver gauge. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 179 It will take a short time for the bulb to light up. Submerge the switch in fuel, and check that the bulb goes out. If operation is not as specified, replace the sender gauge. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 180 Disconnect the connector from the sender gauge. I g n i t i on Turn the ignition switch ON, and check that the receiver Switch gauge needle indicates LOW. Sender Gauge Battery BE1222 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 181 Check that there is no continuity between terminal and the switch set nut with switch pin pushed in. (parking brake lever released) If operation is not as specified, replace the switch. N01212 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 182 ON (belt unfastened). Check that there is no continuity between terminals with the switch OFF (belt fastened). If operation is not as specified, replace the seat belt inner. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 183 ON (float up). Check that there is no continuity between terminals with the switch OFF (float down). If operation is not as specified, replace the switch. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 184 Adjust the brightness of illumination lights by rheostat. A/C Control Assembly Antenna Switch Ash Receptacle Audio Center Diff. Lock Switch Cigarette Lighter Defogger Switch Hazard Warning Switch Shift Lever 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 185 Brought to you by BirfMark BE−42 BODY ELECTRICAL − DEFOGGER SYSTEM DEFOGGER SYSTEM BE1ME−01 LOCATION 1996 LAND CRUISER (RM451U) Author : Date : 1180 Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 186 Place the voltmeter negative (−) lead with the foil strip Broken against the heat wire at the positive (+) terminal end and Wire slide it toward the negative (−) terminal end. BE0124 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 187 Using a fine tip brush, apply a small amount to the wire. After a few minutes, remove the masking tape. Do not repair the defogger wire for at least 24 hours. BE0151 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 188 Brought to you by BirfMark BE−45 BODY ELECTRICAL − POWER WINDOW CONTROL SYSTEM POWER WINDOW CONTROL SYSTEM BE1MG−01 LOCATION 1996 LAND CRUISER (RM451U) Author : Date : 1183 Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 189 7 − 8 − 9 Continuity Rear Right Switch (Window unlock): Switch position Tester connection Specified condition 1 − 2 − 14 Continuity 7 − 8 − 11 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 190 The circuit breaker opens some 4 − 40 seconds after the win- dow stops going down, so that check must be made before the circuit breaker operates. If the operation is as specified, replace the master switch. Z06302 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 191 1 and the negative (−) lead to terminal 2, and check that the motor turns counterclockwise. Reverse the polarity, and check that the motor turns clockwise. If operation is not as specified, replace the motor. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 192 1 and the negative (−) lead to terminal 3, and check that the motor turns clockwise. Reverse the polarity, and check that the motor turns coun- terclockwise. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 193 Specified condition Constant 1 − 3 Continuity Apply B+ between 2 − 4 Continuity terminals 1 and 3. If continuity is not as specified, replace the relay. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 194 Brought to you by BirfMark BE−51 BODY ELECTRICAL − POWER DOOR LOCK CONTROL SYSTEM POWER DOOR LOCK CONTROL SYSTEM BE1MI−01 LOCATION 1996 LAND CRUISER (RM451U) Author : Date : 1189 Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 195 Door key lock and unlock switch is built into the front door lock assembly. INSPECT KEY UNLOCK WARNING SWITCH CONTI- NUITY (See page BE−11) INSPECT DOOR COURTESY SWITCH CONTINUITY (See page BE−21) INSPECT DOOR LOCK MOTOR OPERATION 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 196 After approximately 60 seconds, reverse the polarity, and check that the door lock moves to LOCK position. If operation is not as specified, replace the door lock assembly. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 197 7 − Ground Continuity Key Set) Driver’s door key lock and unlock switch position 9 − Ground No continuity OFF or LOCK (Door key free of turned to lock) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 198 Set the door lock manual switch to LOCK, and check that the voltage rises from 0 V to battery positive voltage for approximately 0.2 seconds. If operation is not as specified, replace the relay. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 199 Open the door, check that the meter needle indicates 0 V. Turn the ignition switch ON, check that the meter needle indicate battery positive voltage again. If operation is not as specified, replace the relay. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 200 Brought to you by BirfMark BE−57 BODY ELECTRICAL − SLIDING ROOF SYSTEM SLIDING ROOF SYSTEM BE1MK−01 LOCATION 1996 LAND CRUISER (RM451U) Author : Date : 1195 Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 201 1 and the negative (−) lead to terminal 3, and check that the motor turns clockwise. Reverse the polarity, and check that the motor turns to clockwise. If operation is not as specified, replace the motor. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 202 Continuity OPEN Sliding roof control switch position (SLIDE) OFF 2 − Ground No continuity or OPEN Sliding roof control switch position (SLIDE) 2 − Ground Continuity CLOSE 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 203 If circuit is as specified, replace the relay. If circuit is not as specified, inspect the circuits connected to oth- er parts. INSPECT POWER MAIN RELAY CONTINUITY (See page BE−46) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 204 Brought to you by BirfMark BE−61 BODY ELECTRICAL − POWER SEAT CONTROL SYSTEM POWER SEAT CONTROL SYSTEM BE1MO−01 LOCATION 1996 LAND CRUISER (RM451U) Author : Date : 1199 Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 205 4 − 10, 7 − 9 Continuity 4 − 7 − 9 Continuity BACKWARD 4 − 9, 7 − 10 Continuity If continuity is not as specified, replace the switch. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 206 Continue to apply voltage, check that there is a circuit breaker operation noise within 4 to 60 seconds. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 207 2 and the negative (−) lead to terminal 1, and check that the motor turns clockwise. Reverse the polarity, and check that the motor turns coun- terclockwise. If operation is not as specified, replace the motor. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 208 4 to 40 seconds. Reverse the polarity, and check that the seat back starts to fall backwards within approximately 60 seconds. If operation is not as specified, replace the motor. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 209 1 and the negative (−) lead to terminal 2, and check that the lumber support moves release side. Reverse the polarity, and check that the lumbar support moves forward. If operation is not as specified, replace the motor. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 210 Reverse the polarity, and check that the lumbar support begins to move release side within approximately 60 se- conds. If operation is not as specified, replace the motor. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 211 Brought to you by BirfMark BE−68 BODY ELECTRICAL − POWER MIRROR CONTROL SYSTEM POWER MIRROR CONTROL SYSTEM BE1MM−01 LOCATION 1996 LAND CRUISER (RM451U) Author : Date : 1206 Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 212 C (Operation) Mirror turns upward Mirror turns downward Mirror turns to left side Mirror turns to right side If operation is not as specified, replace the mirror assembly. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...

  • Page 213: Audio System

    These radio waves then interfere with the signals from the same transmitter that reach the vehicle’s antenna directly. This type of interference is called ”fading”. BE2819 1996 LAND CRUISER (RM451U) Author : Date : 1208 Brought to you by BirfMark...
  • Page 214 Next, using a pencil or similar object, push in the guide. Using a cleaning pen or cotton applicator soaked in clean- er, clean the head surface, pinch rollers and capstans. Pinch Roller N17398 1996 LAND CRUISER (RM451U) Author : Date : 1209 Brought to you by BirfMark...
  • Page 215 NOTICE: Do not use a conventional record cleaner or anti−static pre- servative. BE4331 1996 LAND CRUISER (RM451U) Author : Date : 1210 Brought to you by BirfMark Version 1.00 - 12/21/2010...

  • Page 216: Troubleshooting

    CD will not eject. Antenna Antenna does not fully extend of fully retract. Antenna − related. Noise Noise produced by vibration or shock while driving. Noise produced when engine starts. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 217 Brought to you by BirfMark BE−74 BODY ELECTRICAL − AUDIO SYSTEM 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 218 Brought to you by BirfMark BE−75 BODY ELECTRICAL − AUDIO SYSTEM 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 219 Brought to you by BirfMark BE−76 BODY ELECTRICAL − AUDIO SYSTEM 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 220 Brought to you by BirfMark BE−77 BODY ELECTRICAL − AUDIO SYSTEM 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 221 Brought to you by BirfMark BE−78 BODY ELECTRICAL − AUDIO SYSTEM (See page BE−70) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 222 Brought to you by BirfMark BE−79 BODY ELECTRICAL − AUDIO SYSTEM 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 223 Brought to you by BirfMark BE−80 BODY ELECTRICAL − AUDIO SYSTEM 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 224 Brought to you by BirfMark BE−81 BODY ELECTRICAL − AUDIO SYSTEM 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 225 Brought to you by BirfMark BE−82 BODY ELECTRICAL − AUDIO SYSTEM 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 226 Brought to you by BirfMark BE−83 BODY ELECTRICAL − AUDIO SYSTEM (See page BE−70) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 227 Brought to you by BirfMark BE−84 BODY ELECTRICAL − AUDIO SYSTEM (See page BE−70) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 228 Brought to you by BirfMark BE−85 BODY ELECTRICAL − AUDIO SYSTEM 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 229 Brought to you by BirfMark BE−86 BODY ELECTRICAL − AUDIO SYSTEM 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 230 Brought to you by BirfMark BE−87 BODY ELECTRICAL − AUDIO SYSTEM 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 231 Brought to you by BirfMark BE−88 BODY ELECTRICAL − AUDIO SYSTEM 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 232 Brought to you by BirfMark BE−89 BODY ELECTRICAL − AUDIO SYSTEM 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 233 Brought to you by BirfMark BE−90 BODY ELECTRICAL − AUDIO SYSTEM 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 234 Brought to you by BirfMark BE−91 BODY ELECTRICAL − AUDIO SYSTEM 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 235 Brought to you by BirfMark BE−92 BODY ELECTRICAL − AUDIO SYSTEM 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 236 Brought to you by BirfMark BE−93 BODY ELECTRICAL − AUDIO SYSTEM BE1MQ−01 LOCATION 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 237 (moves upward.) Then, reverse the polarity, check that the motor turns the opposite way (moves downward.) If operation is not as specified, replace the motor. 1996 LAND CRUISER (RM451U) Author : Date : 1232 Brought to you by BirfMark...
  • Page 238 BE1MT−01 TROUBLESHOOTING HINT: Troubleshoot the lock according to the table below. Clock will not operate Clock loses or gains time 1.5 seconds/day 1996 LAND CRUISER (RM451U) Author : Date : 1233 Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 239 Brought to you by BirfMark BE−96 BODY ELECTRICAL − CLOCK 1996 LAND CRUISER (RM451U) Author : Date : 1234 Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 240 HINT: If the clip is damaged during the operation, always replace it with a new clip. Pliers Clip Remover Screwdriver Scraper V00005 1996 LAND CRUISER (RM451U) Author : Date : 1235 Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 241 Brought to you by BirfMark BO−2 BODY − CLIP Shape (Example) Removal / Installation Installation Removal Removal Installation V00012 1996 LAND CRUISER (RM451U) Author : Date : 1236 Brought to you by BirfMark Version 1.00 - 12/21/2010...

  • Page 242: Srs Airbag

    SRS to unexpectedly deploy during servicing, possibly leading to a serious accident. Before servicing (in- cluding removal or installation of parts, inspection or replacement), be sure to read the precautionary notices in the RS section. 1996 LAND CRUISER (RM451U) Author : Date :...

  • Page 243: Front Bumper

    If they are deformed or cracked, re- place them. Torque: 39 N·m (400 kgf·cm, 29 ft·lbf) 1996 LAND CRUISER (RM451U) Author : Date : 1238 Brought to you by BirfMark...

  • Page 244: Rear Bumper

    Brought to you by BirfMark BO−5 BODY − REAR BUMPER REAR BUMPER BO37I−01 COMPONENTS 1996 LAND CRUISER (RM451U) Author : Date : 1239 Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 245 Adjust the hood by loosening the body side hinge bolts. ADJUST HOOD LOCK Adjust the hood lock by loosening the mounting bolts. Torque: 8.0 N·m (80 kgf·cm, 69 in.·lbf) 1996 LAND CRUISER (RM451U) Author : Date : 1240 Brought to you by BirfMark...
  • Page 246 BO5366 Do not turn the piston rod and cylinder with the damp- er stay fully extended. INSTALL DAMPER STAY Install the damper stay. 1996 LAND CRUISER (RM451U) Author : Date : 1241 Brought to you by BirfMark Version 1.00 - 12/21/2010...

  • Page 247: Front Door

    Brought to you by BirfMark BO−8 BODY − FRONT DOOR FRONT DOOR BO37L−01 COMPONENTS 1996 LAND CRUISER (RM451U) Author : Date : 1242 Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 248 Do not block the trim clip sealing with the tape. REMOVE OUTSIDE REAR VIEW MIRROR Cotton Panel Tape REMOVE DOOR GLASS RUN REMOVE REAR LOWER FRAME Cover BO2455 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 249 At the time of reassembly, apply MP grease to the sliding sur- face of the door lock. REMOVE DOOR OUTSIDE HANDLE REMOVE DOOR LOCK CYLINDER REMOVE DOOR SPEAKER 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 250 FRONT DOOR BO37O−01 REPLACEMENT REMOVE GLASS CHANNEL WITH SCREWDRIVER OR LIKE OBJECT APPLY SOAPY WATER TO INSIDE OF WEATH- ERSTRIP INSTALL CHANNEL BY TAPPING IT WITH PLASTIC HAMMER 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 251 Check that the door fit and door lock linkages are adjusted correctly. Loosen the striker mounting screws to adjust. Using a plastic hammer, tap the striker to adjust it. BO2556 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 252 Brought to you by BirfMark BO−13 BODY − FRONT DOOR BO37P−01 REASSEMBLY Reassembly is in the reverse order of disassembly (See page BO−9.) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...

  • Page 253: Rear Door

    Brought to you by BirfMark BO−14 BODY − REAR DOOR REAR DOOR BO37Q−01 COMPONENTS 1996 LAND CRUISER (RM451U) Author : Date : 1248 Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 254 Pry out the clip from the edge of the panel, and remove the moulding. REMOVE DOOR WEATHERSTRIP NOTICE: Do not pull strongly on the weatherstrip as it may tear. REMOVE DOOR INSIDE HANDLE REMOVE SERVICE HOLE COVER 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 255 Torque: 5.0 N·m (50 kgf·cm, 43 in.·lbf) HINT: At the time of reassembly, apply MP grease to the sliding sur- face of the door lock. REMOVE OUTSIDE HANDLE 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 256 REAR DOOR BO37T−01 REPLACEMENT REMOVE GLASS CHANNEL WITH SCREWDRIVER OR LIKE OBJECT APPLY SOAPY WATER TO INSIDE OF WEATH- ERSTRIP INSTALL CHANNEL BY TAPPING IT WITH PLASTIC HAMMER 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 257 Check that the door fit and door lock linkages are adjusted correctly. Loosen the striker mounting screws to adjust. Using a plastic hammer, tap the striker to adjust it. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 258 Brought to you by BirfMark BO−19 BODY − REAR DOOR BO37U−01 REASSEMBLY Reassembly is in the reverse order of disassembly (See page BO−15). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...

  • Page 259: Back Door

    Brought to you by BirfMark BO−20 BODY − BACK DOOR BACK DOOR BO37V−01 COMPONENTS 1996 LAND CRUISER (RM451U) Author : Date : 1254 Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 260 Remove the damper stay. REMOVE LOWER BACK DOOR Remove the door trim. Insert a screwdriver, between the retainers and door trim to pry it loose. Remove the door trim. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 261 BACK DOOR Remove the service hole cover. Remove the door lock control. Panel Remove the door lock. Remove the license plate light cover. Cotton Tape Cover BO2455 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 262 Adjust the door by loosening the door side hinge bolts. Adjust the door in left/right and vertical directions. Adjust the door by loosening the body side hinge bolts. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 263 Check that the door fit and door lock linkages are adjusted correctly. Adjust the striker position by slightly loosening the striker mounting screws, and hitting the striker with a hammer. Tighten the striker mounting screws again. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 264 Brought to you by BirfMark BO−25 BODY − BACK DOOR BO37Y−01 REASSEMBLY Reassembly is in the reverse order of disassembly(See page BO−21). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 265 Do not turn the piston rod and cylinder with the damp- er stay fully extended. INSTALL DAMPER STAY Install the damper stay. 1996 LAND CRUISER (RM451U) Author : Date : 1260 Brought to you by BirfMark...

  • Page 266: Front Wiper And Washer

    Brought to you by BirfMark BO−27 BODY − FRONT WIPER AND WASHER FRONT WIPER AND WASHER BO380−01 COMPONENTS 1996 LAND CRUISER (RM451U) Author : Date : 1261 Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 267 REMOVE WIPER ARMS REMOVE COWL LOUVER REMOVE WIPER MOTOR AND WIPER LINK Disconnect the connector, then unfasten 4 bolts and wip- er motor. Remove the wiper link. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 268 (0.079 − 0.098 in.) tion of the nozzle hole to adjust the point where washer fluid strikes the windshield. 0.7 − 0.75 mm (0.028 − 0.030 in.) BE3367 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 269 Adjust the installation positions of the wiper arms to the positions as shown in the illustration. A: Approx. 25 mm (0.98 in.) Tighten the nuts. Torque: 20 N·m (210 kgf·cm, 15 ft·lbf) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...

  • Page 270: Rear Wiper And Washer

    Remove the 5 bolts and motor, then disconnect the con- nector. Remove the bolts and rear wiper control relay,then dis- connect the connector. ADJUST REAR WASHER NOZZLE 1996 LAND CRUISER (RM451U) Author : Date : 1265 Brought to you by BirfMark...
  • Page 271 Approx. 120 mm (4.72 in.) Approx. 120 mm (4.72 in.) Approx. 90 mm (3.54 in.) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 272 Adjust the installation positions of the wiper arm to the positions shown in the illustration. A: Approx. 40 mm (1.57 in.) Tighten the nut. Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 273 Brought to you by BirfMark BO−34 BODY − BODY OUTSIDE MOULDING BODY OUTSIDE MOULDING BO48L−01 COMPONENTS 1996 LAND CRUISER (RM451U) Author : Date : 1268 Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 274 REMOVE REAR DOOR BELT MOULDING (See page BO−15) REMOVE QUARTER BELT MOULDING Pry out the clips from the edge of the panel, and remove the moulding. BO5153 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 275 Attach the upper edge of the moulding to the body flange. Tap on the moulding by hand. INSTALL FRONT DOOR BELT MOULDING INSTALL REAR DOOR BELT MOULDING INSTALL QUARTER BELT MOULDING 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 276 Brought to you by BirfMark BO−37 BODY − WHEEL OPENING MOULDING WHEEL OPENING MOULDING BO48O−01 COMPONENTS Quarter Outside Moulding Front Fender Wheel Moulding 1996 LAND CRUISER (RM451U) Author : Date : 1271 Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 277 REMOVE REAR WHEEL OPENING MOULDING Remove the 2 bolts and moulding. N14081 REMOVE REAR WHEEL OPENING MOULDING Remove the mud guard, bumper extention and back door scuff plate. N14075 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 278 Remove the quarter trim LH. N14077 REMOVE QUARTER OUTSIDE MOULDING Remove the 2 nuts. N14078 Remove the screw. N14079 Using a screwdriver, pry out the rearwheel moulding. N14440 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 279 Install the screw. Install the quarter trim LH. Install the quarter trim RH. Install the back door scuff plate. Install the rear bumper extension. Install the rear mudguard. N14082 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 280 Brought to you by BirfMark BO−41 BODY − SIDE PROTECTION MOULDING SIDE PROTECTION MOULDING BO38H−01 COMPONENTS 1996 LAND CRUISER (RM451U) Author : Date : 1275 Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 281 Scrape off adhesive from the body with a cutter or sand- paper. NOTICE: Remember that 30−80 mm (1.18−3.15 in.) of the ends of the moulding are glued tightly with a strong adhesive.Do not reuse moulding. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 282 Using a heat light, heat the moulding to 30−60 °C (86−140 °F). NOTICE: Do not heat the moulding excessively. The temperature should not be higher than 80 °C (176 °F). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 283 Scrape off any overflowing adhesive with a plastic spatula and clean the surface with a dry rag. BO5229 After installation, do not wash the vehicle for 24 hours. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 284 Brought to you by BirfMark BO−45 BODY − WINDSHIELD WINDSHIELD BO38P−01 COMPONENTS 1996 LAND CRUISER (RM451U) Author : Date : 1279 Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 285 To prevent scratching the safety pad when removing the windshield, place a plastic sheet between the piano wire and safety pad. Cut the adhesive by pulling the piano wire around it. Remove the glass. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 286 Apply a working cord along the weatherstrip groove, as shown in the illustration. Apply primer to the weatherstrip on the surface with body as shown in the illustration. PRIMER: Sunstar−9002 T or equivalent 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 287 ADHESIVE: Sikaflex−256HV or equivalent CLEANING SEALER SURFACE Apply auto glass sealer dry, remove the masking tape. HINT: The auto glass sealer will harden in about 15 hours. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 288 INSTALL INNER REAR VIEW MIRROR INSTALL COWL LOUVER INSTALL WIPER ARMS Torque: 20 N·m(205 kgf·cm, 15 ft·lbf) INSTALL HOOD Torque: 18 N·m(185 kgf·cm, 13 ft·lbf) ADJUST HOOD (See page BO−6) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 289 Brought to you by BirfMark BO−50 BODY − QUARTER WINDOW GLASS QUARTER WINDOW GLASS BO38S−01 COMPONENTS 1996 LAND CRUISER (RM451U) Author : Date : 1284 Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 290 HINT: Tape the screwdriver tip before use. Pull out the vent louver. Pull out the clips from the edge of the panel, and remove the moulding. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 291 From outside of the vehicle, cut off the weatherstrip lip with a knife. NOTICE: Do not damage the body and the glass. Push the glass outwards and remove the glass. Remove the remaining weatherstrip. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 292 Remove the screw and weatherstrip. REMOVE QUARTER WINDOW GLASS Pull up the sash and remove the 2 glasses. REMOVE QUARTER WINDOW GLASS RUN FROM SASH REMOVE QUARTER WINDOW WEATHERSTRIP FROM SASH 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 293 INSTALL QUARTER WINDOW GLASS RUN INSTALL QUARTER WINDOW GLASS Pull up on the sash and install 2 glasses. INSTALL CENTER SASH Install the weatherstrip with the screw. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 294 INSPECT FOR LEAKS AND REPAIR Do a leak test. Seal any leak with auto glass sealer. INSTALL ROOF HEADLINING INSTALL ASSIST GRIPS INSTALL REAR PILLAR GARNISH INSTALL QUARTER PILLAR GARNISH 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 295 INSTALL REAR DOOR SCUFF PLATE INSTALL REAR SEAT SIDE GARNISH INSTALL QUARTER TRIM INSTALL BACK DOOR SCUFF PLATE w/ No. 2 Rear Seat: INSTALL NO. 2 REAR SEAT 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 296 Brought to you by BirfMark BO−57 BODY − BACK DOOR GLASS BACK DOOR GLASS BO38X−01 COMPONENTS 1996 LAND CRUISER (RM451U) Author : Date : 1291 Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 297 REMOVE WIPER ARM REMOVE DEFOGGER CONNECTOR Disconnect the connector from the glass. REMOVE BACK DOOR GLASS HINT: Remove the glass in the same manner as the windshield. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 298 INSPECT FOR LEAKS AND REPAIR Part No. 08833−00030 or equivalent CONNECT DEFOGGER WIRE CONNECTORS Connect the connector to the glass. CONNECT WIPER ARM Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...

  • Page 299: Sliding Roof

    Brought to you by BirfMark BO−60 BODY − SLIDING ROOF SLIDING ROOF BO390−01 COMPONENTS 1996 LAND CRUISER (RM451U) Author : Date : 1294 Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 300 Brought to you by BirfMark BO−61 BODY − SLIDING ROOF 1996 LAND CRUISER (RM451U) Author : Date : 1295 Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 301 Brought to you by BirfMark BO−62 BODY − SLIDING ROOF 1996 LAND CRUISER (RM451U) Author : Date : 1296 Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 302 REMOVE QUARTER TRIM LH REMOVE REAR SEAT SIDE GARNISH REMOVE REAR DOOR SCUFF PLATE REMOVE COWL SIDE TRIM REMOVE FRONT AND REAR DOOR OPENING TRIM REMOVE CENTER PILLAR LOWER GARNISH 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 303 Remove the 2 screws and switch body, then disconnect the connector. Remove the 2 screws and bracket. REMOVE ROOF HEADLINING Using the clip remover, remove the 7 clips. Remove the roof headlining. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 304 Pull the channel forwards to remove it. REMOVE WIND DEFLECTOR Remove the 4 screws and wind deflector. REMOVE SLIDING ROOF HOUSING Disconnect the drain hose. Remove the 3 nuts, 12 screw and housing. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 305 INSTALL DRIVE GEAR CONTROL RELAY AND BRACKET Install the bracket with 2 bolts. Install the drive gear control relay with the bolt, then con- nect the connector. BO4047 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 306 Pull out the cable guide casing. REMOVE SLIDING GUIDE RAIL Make the drive cable to the front edge. Remove the 4 screws and both side drive rails. Remove the sunshade trim. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 307 Be careful not to lose the spring washer or shim. Manually operate the moon roof by inserting a special crank−shaped screwdriver into the hole and turning the drive shaft. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 308 Slide the bracket to the forefront with your hand. ADJUST RIGHT OR LEFT Adjust by loosening the sliding roof rear shoe installation nuts, and move the sliding roof to the right and left. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 309 Brought to you by BirfMark BO−70 BODY − SLIDING ROOF ADJUST LEFT/RIGHT CLEARANCE Adjust by loosening the sliding roof installation nuts and read- just the sliding roof to the proper position. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 310 Brought to you by BirfMark BO−71 BODY − SLIDING ROOF BO395−01 REASSEMBLY Reassembly is in the reverse order of disassembly (See page BO−67). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 311 Brought to you by BirfMark BO−72 BODY − SLIDING ROOF BO396−01 INSTALLATION Installation is in the reverse order of removal (See pageBO−63 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...

  • Page 312: Instrument Panel

    Brought to you by BirfMark BO−73 BODY − INSTRUMENT PANEL INSTRUMENT PANEL BO397−01 COMPONENTS 1996 LAND CRUISER (RM451U) Author : Date : 1307 Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 313 Brought to you by BirfMark BO−74 BODY − INSTRUMENT PANEL 1996 LAND CRUISER (RM451U) Author : Date : 1308 Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 314 INSTRUMENT PANEL HINT: Screw shapes and size are indicated in the table below.The code (A − N) correspond to those indicated on the previous page. 1996 LAND CRUISER (RM451U) Author : Date : 1309 Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 315 REMOVE NO. 2 CENTER CLUSTER FINISH PANEL REMOVE STEERING COLUMN (See page SR−11) REMOVE CLUSTER FINISH PANEL REMOVE COMBINATION METER REMOVE CENTER CLUSTER FINISH PANEL WITH CLOCK 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 316 Remove the 2 bolts and lower instrument panel reinforce- ment. Remove the 2 bolts, 2 nuts and No. 1 brace. Remove the 4 bolts, 4 nuts and instrument panel rein- forcement. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 317 Never disassemble the front passenger airbag as- sembly. REMOVE NO. 3 CONSOLE MOUNTING BRACKET REMOVE NO. 1 HEATER TO REGISTER DUCT REMOVE NO. 2 STAY 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 318 Brought to you by BirfMark BO−79 BODY − INSTRUMENT PANEL BO39A−01 REASSEMBLY Reassembly is in the reverse order of disassembly (See page BO−78). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 319 Brought to you by BirfMark BO−80 BODY − INSTRUMENT PANEL BO39B−01 INSTALLATION Installation is in the reverse order of removal (See page BO−76). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 320 Brought to you by BirfMark BO−81 BODY − SIDE STEP SIDE STEP BO39C−01 COMPONENTS 1996 LAND CRUISER (RM451U) Author : Date : 1315 Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 321 Brought to you by BirfMark BO−82 BODY − FRONT SEAT (Power Adjuster Type) FRONT SEAT (Power Adjuster Type) BO39E−01 COMPONENTS 1996 LAND CRUISER (RM451U) Author : Date : 1316 Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 322 Brought to you by BirfMark BO−83 BODY − FRONT SEAT (Power Adjuster Type) 1996 LAND CRUISER (RM451U) Author : Date : 1317 Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 323 Torque: 2.0 N·m (20 kgf·cm, 17 in.·lbf) HINT: At the time of installation, apply adhesive to nut. Part No. 08833 − 00070, THREE BOND 1324 or equiva- lent 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 324 Torque: 2.0 N·m (20 kgf·cm, 17 in.·lbf) HINT: At the time of reassembly, apply adhesive to nut. Part No. 08833−00070, THREE BOND 1324 or equiva- lent 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 325 No. 1 vertical seat link. REMOVE FRONT SEAT TRACK Remove the 2 bolts and front seat motor side housing. Torque: 20 N·m (210 kgf·cm, 15 ft·lbf) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 326 RH and LH. Torque: 20 N·m (210 kgf·cm, 15 ft·lbf) Remove the reclining connecting rod. REMOVE SEAT WIRE REMOVE RECLINING MOTOR REMOVE RECLINING HINGE COVER 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 327 Brought to you by BirfMark BO−88 BODY − FRONT SEAT (Power Adjuster Type) BO39H−01 REASSEMBLY Reassembly is in the reverse order of disassembly (See page BO−84). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 328 Brought to you by BirfMark BO−89 BODY − FRONT SEAT (Manual Adjuster Type) FRONT SEAT (Manual Adjuster Type) BO39D−01 COMPONENTS 1996 LAND CRUISER (RM451U) Author : Date : 1323 Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 329 Brought to you by BirfMark BO−90 BODY − REAR NO.1 SEAT REAR NO.1 SEAT BO39J−01 COMPONENTS 1996 LAND CRUISER (RM451U) Author : Date : 1324 Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 330 Brought to you by BirfMark BO−91 BODY − REAR NO.2 SEAT REAR NO.2 SEAT BO39K−01 COMPONENTS 1996 LAND CRUISER (RM451U) Author : Date : 1325 Brought to you by BirfMark Version 1.00 - 12/21/2010...

  • Page 331: Seat Belt

    Brought to you by BirfMark BO−92 BODY − SEAT BELT SEAT BELT BO39L−01 COMPONENTS 1996 LAND CRUISER (RM451U) Author : Date : 1326 Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 332 Make sure that the belt can be pulled out at a tilt of 15 de- (7.87 in.) grees or less, and cannot be pulled out at over 45 degrees of tilt. If a problem is found, replace the assembly. N10070 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...

  • Page 333: Brake System

    It is very important to keep parts and the area clean when repairing the brake system. If the vehicle is equipped with a mobile communication system, refer to the precaution in the IN section. 1996 LAND CRUISER (RM451U) Author : Date : Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 334 2. Pad: oily BR−21 BR−30 3. Piston: frozen BR−33 Brake pull BR−33 4. Disc: Scored BR−33 BR−33 5. Pad: cracked or distorted BR−21 BR−30 1996 LAND CRUISER (RM451U) Author : Date : Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 335 7. Pad: glazed BR−21 BR−30 8. Tension or return spring: faulty BR−39 9. Anti−squeal shim: damaged BR−21 BR−30 10.. Hold−down spring: damaged BR−39 1996 LAND CRUISER (RM451U) Author : Date : Brought to you by BirfMark Version 1.00 - 12/21/2010...

  • Page 336: Brake Fluid

    Begin bleeding air from the brake caliper with the longest hydraulic line. BLEED BRAKE LINE Slowly depress the brake pedal several times. R00252 1996 LAND CRUISER (RM451U) Author : Date : Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 337 Repeat this procedure until there are no more air bubbles in the fluid. Bleeder plug tightening torque: 11 N·m (110 kgf·cm, 8 ft·lbf) REPEAT PROCEDURE FOR EACH WHEEL BLEED LSP & BV 1996 LAND CRUISER (RM451U) Author : Date : Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 338 The freeplay to the 1st resistance is due to the play between the clevis and pin. This is magnified up to 3 − 6 mm (0.12 − 0.24 in.) BR0016 at the pedal. 1996 LAND CRUISER (RM451U) Author : Date : Brought to you by BirfMark...
  • Page 339 Pedal reserve distance, ’a’, at 490 N (50 kgf, 110.2lbf): More than 68 mm (2.68 in.) If the reserve distance incorrect, troubleshoot the brake sys- tem. BR3297 1996 LAND CRUISER (RM451U) Author : Date : Brought to you by BirfMark Version 1.00 - 12/21/2010...

  • Page 340: Parking Brake Lever

    Loosen the lock nut and turn the adjusting nut until the le- ver travel is correct. Tighten the lock nut. BR4775 Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf) Install the rear console box. 1996 LAND CRUISER (RM451U) Author : Date : Brought to you by BirfMark Version 1.00 - 12/21/2010...

  • Page 341: Brake Master Cylinder

    Brought to you by BirfMark BR-9 BRAKE BRAKE MASTER CYLINDER BRAKE MASTER CYLINDER BR1CH-01 COMPONENTS 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 342 Remove the 4 nuts. Torque: 13 N·m (130 kgf·cm, 9 ft·lbf) Remove the 3-way, check valve bracket, wire harness clamp and bracket. Pull out the master cylinder and gasket. R13591 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 343 No.2 piston drops out of the cylinder. HINT: Make sure that the distance (A) from the rag to the top of the blocks is at least 100 mm (3.94 in.). R12236 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 344 Clean the disassembled parts with compressed air. INSPECT CYLINDER BORE FOR RUST OR SCORING INSPECT CYLINDER FOR WEAR OR DAMAGE If necessary, clean or replace the cylinder. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 345 REASSEMBLY Reassembly is in the reverse order of disassembly. NOTICE: Apply lithium soap base glycol grease to the rubber parts indicated by the arrows (See page BR-9 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 346 Before installation, adjust length of brake booster push rod (See page BR-18 After installation, fill brake reservoir with brake fluid, bleed brake system (See page BR-4 Check for leaks, check and adjust brake pedal (See page BR-6 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...

  • Page 347: Brake Booster Assembly

    If there is no change in the pedal reserve travel after holding the pedal for 30 seconds, the booster is air tight. BR2238 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 348 Brought to you by BirfMark BR-16 BRAKE BRAKE BOOSTER ASSEMBLY BR1CO-01 COMPONENTS 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 349 If there is no change in the pedal reserve travel after holding the pedal for 30 seconds, the booster is air tight. BR2238 1996 LAND CRUISER (RM451U) Author : Date : Brought to you by BirfMark...
  • Page 350 Brought to you by BirfMark BR−18 BRAKE − BRAKE BOOSTER ASSEMBLY BR1CO−02 COMPONENTS 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 351 REMOVE THESE PARTS: Return spring Clip and clevis pin Clevis Vacuum hose REMOVE BRAKE BOOSTER Remove the 4 booster installation nuts. Remove the booster and gasket. BR3753 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 352 FILL BRAKE RESERVOIR WITH BRAKE FLUID AND BLEED BRAKE SYSTEM (See page BR−4) CHECK FOR FLUID LEAKAGE CHECK AND ADJUST BRAKE PEDAL (See page BR−6) DO OPERATIONAL CHECK (See page BR−17) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...

  • Page 353: Front Brake Pad

    Brought to you by BirfMark BR−21 BRAKE − FRONT BRAKE PAD FRONT BRAKE PAD BR1CR−01 COMPONENTS 1996 LAND CRUISER (RM451U) Author : Date : 1003 Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 354 If the piston is difficult to push in, loosen the bleeder plug and push in the piston while letting some brake fluid es- cape. Install the 2 anti−squeal shims to new pads. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 355 Do not allow oil or grease to get on the rubbing face. INSTALL ANTI−RATTLE SPRING AND 2 PINS INSTALL CLIP INSTALL FRONT WHEEL CHECK THAT FLUID LEVEL IS AT MAX LINE 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...

  • Page 356: Front Brake Caliper

    Brought to you by BirfMark BR−24 BRAKE − FRONT BRAKE CALIPER FRONT BRAKE CALIPER BR1CT−01 COMPONENTS 1996 LAND CRUISER (RM451U) Author : Date : 1006 Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 357 Remove the 2 mounting bolts and caliper. Torque: 123 N·m (1,250 kgf·cm, 90 ft·lbf) REMOVE THESE PARTS: Clip 2 pins Anti−rattle spring 2 pads 4 anti−squeal shims 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 358 Do not place your fingers in front of the pistons when using compressed air. BR0213 REMOVE PISTON SEALS Using a screwdriver, remove the 4 piston seals from the cylin- der. BR2009 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 359 Install a new disc and torque the bolts. Torque: 74 N·m (750 kgf·cm, 54 ft·lbf) Install the axle hub and adjust the front bearing preload (See page SA−9). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 360 Reassembly is in the reverse order of disassembly (See page BR−26). NOTICE: Apply lithium soap base glycol grease to the parts indicated by the arrows (See page BR−33). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 361 Installation is in the reverse order of removal (See page BR−25). HINT: After installation, fill the brake reservoir with brake fluid, bleed brake system (see page BR−4) and check for leaks. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...

  • Page 362: Rear Brake Pad

    Brought to you by BirfMark BR−30 BRAKE − REAR BRAKE PAD REAR BRAKE PAD BR1CZ−02 COMPONENTS 1996 LAND CRUISER (RM451U) Author : Date : 1012 Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 363 (See page BR−36) INSTALL PAD SUPPORT PLATES INSTALL NEW PADS NOTICE: When replacing worn pads, the anti−squeal shim and wear indicator plates must be replaced together with the pads. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 364 Install and torque the sliding main pin and sub pin. Torque: 88 N·m (900 kgf·cm, 65 ft·lbf) INSTALL REAR WHEEL CHECK THAT FLUID LEVEL IS AT MAX LINE 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...

  • Page 365: Rear Brake Caliper

    Brought to you by BirfMark BR−33 BRAKE − REAR BRAKE CALIPER REAR BRAKE CALIPER BR1D1−01 COMPONENTS 1996 LAND CRUISER (RM451U) Author : Date : 1015 Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 366 REMOVE CALIPER Remove the 2 sliding pins and caliper. Torque: 88 N·m (900 kgf·cm, 65 ft·lbf) REMOVE THESE PARTS: 2 pads with anti−squeal shim 4 pad support plates 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 367 Using a screwdriver, remove the piston seal from the cylinder. REMOVE DUST BOOT AND SLIDING BUSHING Using a screwdriver and hammer, tap out dust boot and sliding bushing. HINT: Tape the screwdriver tip before use. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 368 Install a new disc and and loosely install the hub nuts. Install the torque plate and tighten the mounting bolts. Torque: 103 N·m (1,050 kgf·cm, 76 ft·lbf) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 369 Reassembly is in the reverse order of disassembly (See page BR−35). NOTICE: Apply lithium soap base glycol grease to the parts indicated by the arrows (See page BR−33). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 370 Installation is in the reverse order of removal (See page BR−34). HINT: After installation, fill brake reservoir with brake fluid, bleed brake system (See pageBR−4) and check for leaks. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...

  • Page 371: Parking Brake

    Brought to you by BirfMark BR−39 BRAKE − PARKING BRAKE PARKING BRAKE BR1D7−01 COMPONENTS 1996 LAND CRUISER (RM451U) Author : Date : 1021 Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 372 Using SST, remove the shoe return springs. 09717−20010 HINT: Using SST, install the front shoe return spring and then install the rear return spring. 09718−20010 REMOVE SHOE STRUT WITH SPRING 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 373 Torque: 13 N·m (130 kgf·cm, 9 ft·lbf) Remove the boot from parking brake bellcrank bracket. Using a screwdriver, remove the C−washer and pin. Remove the parking brake bellcrank from the bell crank bracket. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 374 If the clearance is not within the specification, replace the shim with one of the correct size. Shim Thickness Shim Thickness 0.3 mm (0.012 in.) 0.9 mm (0.035 in.) Clearance R00343 0.6 mm (0.024 in.) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 375 Remove the parking brake shoe lever, and install the cor- rect size shim. Using needle−nose pliers, install the parking brake shoe lever with a new C−washer. Remeasure the clearance. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 376 88 N (9 kgf, 19.8 lbf) of force. Drive the vehicle for about 400 meters (0.25 mile) in this condition. Repeat this procedure 2 or 3 times. RECHECK AND ADJUST PARKING BRAKE LEVER TRAVEL 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 377 Torque the 2 nuts. Torque: 13 N·m (130 kgf·cm, 9 ft·lbf) Adjust the length of the No.2 shackle again. If it cannot be adjusted, inspect the valve housing. 1996 LAND CRUISER (RM451U) Author : Date : 1027 Brought to you by BirfMark...
  • Page 378 5,396 (55, 783) 3,630 − 4,218 (37 − 43, 527 − 612) 9,810 (100, 1,424) 4,513 − 5,494 (46 − 56, 655 − 797) 1996 LAND CRUISER (RM451U) Author : Date : 1028 Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 379 Brought to you by BirfMark BR−47 BRAKE − LOAD SENSING PROPORTIONING AND BY−PASS VALVE (LSP & BV) LOAD SENSING PROPORTIONING AND BY−PASS VALVE (LSP & BV) BR1DB−01 COMPONENTS 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 380 Using SST, disconnect the 3 brake lines from the valve body. 09751−36011 Remove the valve bracket and 4 mounting bolts, then re- move the LSP & BV assembly. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 381 Loosen the 2 nuts, and remove the shackle No.1 from the shackle No.2. DISASSEMBLE LOAD SENSING SPRING Disassembly the these parts: 4 bushings 2 collars 2 rubber plates Load sensing valve boot Load sensing spring boot 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 382 LOAD SENSING PROPORTIONING AND BY−PASS VALVE (LSP & BV) BR1DF−01 INSPECTION INSPECT VALVE PISTON PIN AND LOAD SENSING SPRING CONTACT SURFACE FOR WEAR Wear limit: 0.7 mm (0.028 in.) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 383 2 valve body mounting nuts. Torque the bolt and nut through the 2 plate washers. Torque: 18 N·m (185 kgf·cm, 13 ft·lbf) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 384 Torque: 13 N·m (130 kgf·cm, 9 ft·lbf) BLEED BRAKE SYSTEM (See page BR−4) CHECK FLUID LEAKAGE CHECK AND ADJUST LSP & BV FLUID PRESSURE (See page BR−45) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 385 Connect the red cable of the checker to the battery posi- tive (+) terminal and black cable to the negative (−) termi- nal. Connect the black cable of the sub−wire harness to the battery negative (−) terminal or body ground. 1996 LAND CRUISER (RM451U) Author : Date : 1035 Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 386 Similarly, inspect ”REAR” position. PUSH SUB MOTOR SWITCH Push and hold in the SUB MOTOR switch for a few se- conds. Stop the engine. 1996 LAND CRUISER (RM451U) Author : Date : 1036 Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 387 Connect the 2 connectors to the control relay. Connect the connector to the actuator. BR1334 Install the control relay to the actuator bracket. CLEAR DTC (See page DI−190) 1996 LAND CRUISER (RM451U) Author : Date : 1037 Brought to you by BirfMark...
  • Page 388 Brought to you by BirfMark BR−56 BRAKE − ABS ACTUATOR BR1DJ−01 COMPONENTS 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 389 Remove the 3 nuts and actuator from the actuator brack- Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf) Remove the 3 holders and cushions from the ABS actua- tor. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 390 Check there is continuity between terminal 2 and 6. Check there is no continuity between terminals 2 and 6. If operation is not as specified, replace the relay. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 391 Installation is in the reverse order of removal (See page BR−57). HINT: After installation, fill the brake reservoir with brake fluid, bleed brake system (see page BR−4) and check for leaks. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...

  • Page 392: Front Speed Sensor

    Brought to you by BirfMark BR−60 BRAKE − FRONT SPEED SENSOR FRONT SPEED SENSOR BR1DM−02 COMPONENTS 1996 LAND CRUISER (RM451U) Author : Date : 1042 Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 393 Remove the bolt and 2 clips holding the sensor harness from the frame and body. Remove the 2 installation bolts and speed sensors from the steering knuckle. Torque: 18 N·m (185 kgf·cm, 13 ft·lbf) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 394 Inspect the sensor rotor serrations for scratches, cracks, warping or missing teeth. Install the axle hub with disc SA−9). NOTICE: To prevent damage to the serrations, do not strike the axle hub. R04759 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 395 Brought to you by BirfMark BR−63 BRAKE − FRONT SPEED SENSOR CHECK THAT THERE IS NO FOREIGN OBJECT ON SENSOR CHECK SPEED SENSOR SIGNAL (See page DI−210) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 396 FRONT SPEED SENSOR BR1DO−01 INSTALLATION Installation is in the reverse order of removal (See page BR−61). HINT: After installation, check the speed sensor signal (See page DI−190). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...

  • Page 397: Rear Speed Sensor

    Brought to you by BirfMark BR−65 BRAKE − REAR SPEED SENSOR REAR SPEED SENSOR BR1DP−02 COMPONENTS 1996 LAND CRUISER (RM451U) Author : Date : 1047 Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 398 REMOVE SPEED SENSOR Remove the installation bolt and speed sensor from the axle end. Torque: 18 N·m (185 kgf·cm, 13 ft·lbf) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 399 Inspect the sensor rotor serrations for scratches, cracks, warping or missing teeth. Install the brake disc. NOTICE: To prevent damage to the serrations, do not strike the axle hub. R04775 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 400 Brought to you by BirfMark BR−68 BRAKE − REAR SPEED SENSOR CHECK THAT THERE IS NO FOREIGN OBJECT ON SENSOR CHECK SPEED SENSOR SIGNAL (See page DI−210) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 401 REAR SPEED SENSOR BR1DR−01 INSTALLATION Installation is in the reverse order of removal (See page BR−66). HINT: After installation, check the speed sensor signal (see page DI−190). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 402 Disconnect the battery cables when the battery is given a quick charge. Do not perform tests with a high voltage insulation resistance tester. Never disconnect the battery while the engine is running. 1996 LAND CRUISER (RM451U) Author : Date : Brought to you by BirfMark Version 1.00 - 12/21/2010...

  • Page 403: Charging System

    Check the indicator as shown in the illustration. Blue White Charging Add Distilled Necessary Water CH0712 CHECK BATTERY TERMINALS, FUSIBLE LINK AND FUSES Check that the battery terminals are not loose or cor- roded. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 404 INSPECT DISCHARGE WARNING LIGHT CIRCUIT Turn the ignition switch ”ON”. Check that the discharge warning light comes on. Start the engine. Check that the light goes off. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 405 INSPECT CHARGING CIRCUIT WITH LOAD With the engine running at 2,000 rpm, turn on the high beam headlights and place the heater blower switch at ”HI”. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 406 If the ammeter reading is less than standard amperage, repair the generator. HINT: If the battery is fully charged, the indication will sometimes be less than standard amperage. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 407 Brought to you by BirfMark CH−6 CHARGING − GENERATOR GENERATOR CH06H−05 COMPONENTS 1996 LAND CRUISER (RM451U) Author : Date : Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 408 Brought to you by BirfMark CH−7 CHARGING − GENERATOR 1996 LAND CRUISER (RM451U) Author : Date : Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 409 Disconnect the generator wire clamp from the generator. Remove the lock bolt, bolt, nut and drive belt adjusting bar. Remove the pivot bolt and generator. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 410 REMOVE BRUSH HOLDER Remove the brush holder cover from the brush holder. Remove the 2 screws and brush holder. REMOVE VOLTAGE REGULATOR Remove the 3 screws and voltage regulator. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 411 Check that SST (A) is secured to the rotor shaft. Hold P03807 Mount SST (C) in a vise. Install the generator to SST (C). SST (C) P08242 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 412 REMOVE RECTIFIER END FRAME Remove the 4 nuts. Using SST, remove the rectifier end frame. 09286−46011 Remove the generator washer. P03794 REMOVE ROTOR FROM DRIVE END FRAME 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 413 Using an ohmmeter, check that there is no continuity between No Continuity the coil lead and drive end frame. If there is continuity, replace the drive end frame assembly. Ohmmeter P00482 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 414 Z04144 INSPECT FRONT BEARING Check that the bearing is not rough or worn. P00644 INSPECT REAR BEARING Check that the bearing is not rough or worn. CH1026 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 415 REPLACE REAR BEARING Using SST, remove the bearing cover (outside) and bear- ing. 09820−00021 NOTICE: Be careful not to damage the fan. Remove the bearing cover (inside). N00581 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 416 Place the bearing cover (inside) on the rotor. Bearring Cover P05052 Using SST and a press, press in a new bearing. 09820−00030 N00578 Using SST, push in the bearing cover (outside). 09285−76010 P00074 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 417 Torque: 39 N·m (400 kgf·cm, 29 ft·lbf) Check that SST (A) is secured to the pulley shaft. P03807 Mount SST (C) in a vise. Install the generator to SST (C). SST (C) P08242 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 418 Torque: 2.9 N·m (30 kgf·cm, 25 in.·lbf) INSTALL VOLTAGE REGULATOR Install the voltage regulator on the rectifier end frame with the 3 screws. Torque: 2.0 N·m (20 kgf·cm, 17 in.·lbf) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 419 Bolt: 3.8 N·m (39 kgf·cm, 34 in.·lbf) Nut: 4.4 N·m (45 kgf·cm, 39 in.·lbf) Install the terminal insulator with the nut. Torque: 4.1 N·m (42 kgf·cm, 36 in.·lbf) CHECK THAT ROTOR ROTATES SMOOTHLY 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 420 Pivot bolt: 59 N·m (600 kgf·cm, 43 ft·lbf) Lock bolt: 21 N·m (210 kgf·cm, 15 ft·lbf) CONNECT POWER STEERING (PS) RESERVOIR TANK INSTALL BATTERY TRAY AND BATTERY PERFORM ON−VEHICLE INSPECTION (See page CH−2) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 421 There should not be any excessive deposits of rust or scale around the radiator cap or radiator filler hole, and the coolant should be free from oil. If excessively dirty, replace the coolant. Reinstall the radiator cap. 1996 LAND CRUISER (RM451U) Author : Date : Brought to you by BirfMark...
  • Page 422 14.7 liters (15.5 US qts, 12.9 lmp. qts) Reinstall the radiator cap. Warm up the engine and check for leaks. Recheck the coolant level and refill as necessary. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...

  • Page 423: Water Pump

    Brought to you by BirfMark CO−3 COOLING − WATER PUMP WATER PUMP CO111−01 COMPONENTS 1996 LAND CRUISER (RM451U) Author : Date : Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 424 Pull out the fan with fluid coupling, water pump pulley and fan shroud. Remove the fan from the fluid coupling. REMOVE WATER PUMP Remove the 4 bolts, 2 nuts, water pump and gasket. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 425 If necessary, replace the water pump. INSPECT FLUID COUPLING Check the fluid coupling for damage and silicon oil leakage. If necessary, replace the fluid coupling. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 426 Adjust the drive belts (See page CH−2). CONNECT NO.3 WATER BYPASS HOSE CONNECT RADIATOR INLET HOSE FILL RADIATOR WITH ENGINE COOLANT START ENGINE AND CHECK FOR LEAKS 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 427 Brought to you by BirfMark CO−7 COOLING − THERMOSTAT THERMOSTAT CO0IU−03 COMPONENTS 1996 LAND CRUISER (RM451U) Author : Date : Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 428 Removal of the thermostat would have an adverse effect, causing a lowering of cooling efficiency. Do not remove the thermostat, even if the engine tends to overheat. DRAIN ENGINE COOLANT REMOVE WATER INLET AND THERMOSTAT 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 429 If the valve lift is not as specified, replace the thermostat. Check that the valve is fully closed when the thermostat is at low temperatures (below 40°C (104°F)). If not closed, replace the thermostat. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 430 INSTALL WATER INLET Install the water inlet with the 3 nuts. Torque: 21 N·m (210 kgf·cm, 15 ft·lbf) FILL RADIATOR WITH ENGINE COOLANT START ENGINE AND CHECK FOR LEAKS 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 431 NOTICE: If using a high pressure type cleaner, be careful not to deform the fins of the radiator core. (i.e. Main- tain a distance between the cleaner nozzle and radiator core) 1996 LAND CRUISER (RM451U) Author : Date : Brought to you by BirfMark...
  • Page 432 If the pressure drops, check the hoses, radiator or water pump for leaks. If no external leaks are found, check the heater core, cylinder block and head. REINSTALL RADIATOR CAP 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 433 Brought to you by BirfMark CO−13 COOLING − RADIATOR CO0J0−03 COMPONENTS 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 434 Remove the 4 water pump pulley mounting nuts. Pull out the fan with fluid coupling, water pump pulley and fan shroud. DISCONNECT A/T OIL COOLER HOSES DISCONNECT RADIATOR OUTLET HOSE 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 435 Brought to you by BirfMark CO−15 COOLING − RADIATOR REMOVE RADIATOR Remove the 2 bolts, 2 nuts and radiator. Remove the 4 nuts and 2 radiator brackets. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 436 Install the battery with the hold−down clamp and nuts. Connect the battery cables. FILL RADIATOR WITH ENGINE COOLANT START ENGINE AND CHECK FOR LEAKS CHECK AUTOMATIC TRANSMISSION FLUID LEVEL 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 437 See the indicated pages for detailes explanations. Customer Problem Analysis P. DI−2 Connect the OBD II scan tool or TOYOTA hand−held tester to DLC3 P. DI−3 If the display indicates a communication fault in the tool, inspect DLC3 P. DI−3 Check DTC and Freezed Frame Data (Precheck) Record or Print DTC and Freezed Frame Data P.
  • Page 438 Does not light up Normal Malfunction code(s) (code Normal mode (Precheck) Freezed frame data ( DTC Inspection Normal Malfunction code(s) (code Check Mode Freezed frame data ( 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 439 When troubleshooting OBD II vehicles, the only dif- ference from the usual troubleshooting procedure is that you connect to the vehicle the OBD II scan tool complying with SAE J1978 or TOYOTA hand− held tester, and read off various data output from the vehicle’s ECM.
  • Page 440 ECM to check mode when troubleshooting, the technician can cause the MIL to light up for a mal- function that is only detected once or momentarily (TOYOTA hand−held tester only) (See step 2). *2 trip detection logic: When a logic malfunction is first detected, the mal- function is temporarily stored in the ECM memory.
  • Page 441 If your display shows ”UNABLE TO CONNECT TO VEHICLE” when you have connected the cable of the OBD II scan tool or TOYOTA hand−held tester to DLC3, turned the ignition switch ON and operated the scan tool, there is a problem on the ve- hicle side or tool side.
  • Page 442 NOTICE: When simulating symptoms with an OBD II scan tool (ex- cluding TOYOTA hand−held tester) to check the DTC, use normal mode. For codes on the DTC chart subject to ”2 trip detection logic”, turn the ignition switch OFF after the symptom is simulated the first time.
  • Page 443 Disconnecting the battery terminals or EFI fuse. NOTICE: If the TOYOTA hand−held tester switches the ECM from normal mode to check mode or vice−versa, or if the igni- tion switch is turned from ON to ACC or LOCK during check mode, the DTCs and freezed frame data will be erased.
  • Page 444 HINT: If necessary, clean the element with compressed air. First blow from inside thoroughly, then blow from outside of element. Outside P04771 Repair or replace 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 445 Switch off all accessories. Switch off air conditioning. Shift transmission into ”N” position. Connect the OBD II scan tool or TOYOTA hand−held tester to DLC3 on the vehicle. CHECK: Use CURRENT DATA to check the idle speed. Idle speed: 650 ± 50 rpm Proceed to matrix chart of problem symptoms on page DI−19.
  • Page 446 Turn ignition switch ON and push TOYOTA hand−held tester main switch ON. Use ACTIVE TEST mode to operate the fuel pump. If you have no TOYOTA hand−held tester, connect the positive (+) and negative (−) leads from the battery to the fuel pump connector (See page SF−6).
  • Page 447 : If no conditions are specifically stated for ”ldling”, it means the shift lever is at N or P position, the A/C switch is OFF and all accessory switches are OFF. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark...
  • Page 448 : If no conditions are specifically stated for ”ldling”, it means the shift lever is at N or P position, the A/C switch is OFF and all accessory switches are OFF. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark...
  • Page 449 (Bank 1 Sensor 2) Heated Oxygen Sensor Heater P0141 Circuit Malfunction S Same as DTC No. P0135 f *1 (DI−47) (Bank 1 Sensor 2) *1: MIL lights up 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 450 S Open in VSV circuit for EGR f *1 (DI−80) Flow Excessive Detected S Short in EGR gas temp. sensor circuit S ECM *1: MIL lights up *2: MIL lights up or blinking 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 451 S Short in park/neutral position switch circuit P1780 Park/Neutral Position Switch S Park/neutral position switch (DI−108) Malfunction S ECM *: − @@@ MIL does not light up, @@@ MIL lights up 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 452 Brought to you by BirfMark DI−16 DIAGNOSTICS − ENGINE DI5OW−03 PARTS LOCATION A15824 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 453 (See page DI−54) IG switch ON 9 − 14 #60 (E4 − 15) − E01 (E4 − 13) Y − L ↔ BR Pulse generation Idling (See page DI−54) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 454 Restarting at high engine coolant temp. 0 − 3 SDL (E7 − 6) − E1 (E4 − 24) W ↔ BR − B During transmission Pulse generation 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 455 Soon after starting (Engine stall) 1. Fuel pump control circuit DI−115 1. A/C signal circuit AC−5 During A/C operation (Engine stall) 2. Engine control module (ECM) IN−18 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 456 HINT: After confirming DTC P0100 use the OBD II scan tool or TOYOTA hand−held tester to confirm the mass air flow ratio from ”CURRENT DATA”. Mass Air Flow Value (gm/sec.)

  • Page 457: Wiring Diagram

    Brought to you by BirfMark DI−21 DIAGNOSTICS − ENGINE WIRING DIAGRAM R−Y Y−R MRLY EFI Main Relay R/B No.2 Fusible Link Battery Mass Air Flow Meter P22419 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...

  • Page 458: Inspection Procedure

    Remove the fuse cover on the instrument panel. Connect the OBD II scan tool or TOYOTA hand−held tester to the DLC3. Turn ignition switch ON and OBD II scan tool or TOYOTA hand−held tester main switch ON. Start the engine.
  • Page 459 Check for open and short in harness and connector between mass air flow meter and ECM (See page IN−28). Repair or replace harness or connector. Replace mass air flow meter. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 460 Check for open in harness and connector between mass air flow meter and ECM (See page IN−28). Repair or replace harness or connector. Replace mass air flow meter. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 461 DI−20 for the WIRING DIAGRAM. INSPECTION PROCEDURE Are there any other codes (besides DTC P0101) being output? Go to relevant DTC chart. Replace mass air flow meter. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 462 Open or short in intake air temp. sensor circuit S Intake air temp. sensor S ECM HINT: After confirming DTC P110 use the OBD II scan tool or TOYOTA hand−held tester to confirm the intake air temp. from ”CURRENT DATA”. Temp. Displayed Malfunction −...
  • Page 463 Same as actual intake air temp. HINT: If there is open circuit, push OBD II scan tool or TOYOTA hand−held tester indicates − 40°C (− 40°F). If there is short circuit, OBD II scan tool or TOYOTA hand−held tester indicates 140°C (284°F) or more.
  • Page 464 Disconnect the mass air flow meter connector. Connect sensor wire harness terminals together. Intake Air Turn ignition switch ON. Temp. Sensor CHECK: Read temp. value on the OBD II scan tool or TOYOTA hand− held tester. BE6653 Temp. value: 140°C (284°F) or more FI7055 A00154 A00154 Confirm good connection at sensor.
  • Page 465 PREPARATION: Disconnect the mass air flow meter connector. Turn ignition switch ON. Intake Air CHECK: Temp. Sensor Read temp. value on the OBD II scan tool or TOYOTA hand− held tester. Temp. value: − 40°C (− 40°F) BE6653 FI7054 A00151 Replace mass air flow meter.
  • Page 466 Open or short in engine coolant temp. sensor circuit S Engine coolant temp. sensor S ECM HINT: After confirming DTC P0115 use the OBD II scan tool or TOYOTA hand−held tester to confirm the engine coolant temp. from CURRENT DATA. Temp. Displayed Malfunction −...
  • Page 467 Remove the fuse cover on the instrument panel. Connect the OBD II scan tool or TOYOTA hand−held tester to the DLC3. Turn ignition switch ON and push the OBD II scan tool or TOYOTA hand−held tester main switch ON. CHECK: Read temperature value on the OBD II scan tool or TOYOTA hand−held tester.
  • Page 468 Engine coolant temp. sensor connector is disconnected. Be- fore checking, do a visual and contact pressure check for the ECM connector (See page IN−28). Turn ignition switch ON. CHECK: Read temperature value on the OBD II scan tool or TOYOTA hand−held tester. BE6653 FI7057 P24656 A00157 Temperature value: 140°C (284°F) or more...
  • Page 469 Disconnect the E5 connector of ECM. HINT: Engine coolant temp. sensor connector is disconnected. Turn ignition switch ON. CHECK: Read temperature value on the OBD II scan tool or TOYOTA hand−held tester. Temperature value: − 40°C (− 40°F) E5 connector BE6653...
  • Page 470 Are there any other codes (besides DTC P0116) being output? Go to relevant DTC chart. Check thermostat (See page CO−9). Replace the thermostat. Replace engine coolant temp. sensor. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 471 If there is open circuit in IDL line, DTC P0120 does not indicate. After confirming DTC P0120 use the OBD II scan tool or TOYOTA hand−held tester to confirm the throttle valve opening percentage and closed throttle position switch condition.
  • Page 472 Remove the fuse cover on the instrument panel. Connect the OBD II scan tool or TOYOTA hand−held tester to DLC3. Turn ignition switch ON and push the OBD II scan tool or TOYOTA hand−held tester main switch ON. CHECK: Read the throttle valve opening percentage.
  • Page 473 Voltage: 4.5 − 5.5 V BE6653 P24657 A00160 Go to step 5. Check throttle position sensor (See page SF−42). Replace throttle position sensor. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 474 Voltage: 4.5 − 5.5 V P24659 A00162 Check and replace ECM (See page IN−28). Check for open in harness and connector between ECM and sensor (VCC line) (See page IN−28). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 475 (19 mph) and 0 km/h (0 mph). INSPECTION PROCEDURE Are there any other codes (besides DTC P0121) being output? Go to relevant DTC chart. Replace throttle position sensor. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 476 (a) Engine speed: 1,500 rpm or more S Heated oxygen sensor (bank1 sensor 1) (b) Vehicle speed: 40 − 100 km/h (25 − 62 mph) (c) Closed throttle position switch: OFF 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 477 ENGINE HINT: After confirming DTC P0125 use the OBD II scan tool or TOYOTA hand−held tester to confirm voltage output of heated oxygen sensor (bank 1 sensor 1) from CURRENT DATA. If voltage output of heated oxygen sensor (bank 1 sensor 1) is 0 V, heated oxygen sensor (bank 1 sensor 1) circuit may be open or short.
  • Page 478 DIAGNOSTICS − ENGINE INSPECTION PROCEDURE Connect the OBD II scan tool or TOYOTA hand−held tester and read value for voltage output of heated oxygen sensor). PREPARATION: Remove the fuse cover on the instrument panel. Connect the OBD II scan tool or TOYOTA hand−held tester to the DLC3.
  • Page 479 If the conditions in this test are not strictly followed, detection of the malfunction will not be possible. If you do not have a TOYOTA hand−held tester, turn the ignition switch OFF after performing steps (3) to (5), then perform steps (3) to (5) again.
  • Page 480 Check for heated oxygen sensor (bank 1 sensor 1) data. PREPARATION: Remove the fuse cover on the instrument panel. Connect the OBD II scan tool or TOYOTA hand−held tester to the DLC3. Warm up engine to normal operating temp. CHECK: Read the heated oxygen sensor (bank 1 sensor 1) output voltage and short−term fuel trim.
  • Page 481 Warm up the heated oxygen sensor (bank 1 sensor 1) with the engine at 2,500 rpm for approx. 90 sec. CHECK: Use the OBD II scan tool or TOYOTA hand−held tester read the output voltage of the heated oxygen sensor (bank 1 sensor 1) during idling.
  • Page 482 Sensor 1 refers to the sensor closer to the engine body. INSPECTION PROCEDURE Are there any other codes (besides DTC P0133) being output? Go to relevant DTC chart. Replace heated oxygen sensor (bank 1 sensor 1). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 483 Connect terminal HT1 to bank 1 sensor 1. BE6653 P24460 A00950 Connect terminal HT2 to bank 1 sensor 2. Voltage: 9 − 14 V Check and replace ECM (See page IN−28). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 484 Replace heated oxygen sensor. Check and repair harness or connector between EFI main relay (Marking: EFI) and heated oxygen sensor (bank 1 sensor 1, 2) and ECM (See page IN−28). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 485 Check for open and short in harness and connector between ECM and heated oxygen sensor (bank 1 sensor 2) (See page IN−28). Repair or replace harness or connector. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 486 Check the output voltage of heated oxygen sensor (bank 1 sensor 2). PREPARATION: Remove the fuse cover on the instrument panel. Connect the OBD II scan tool or TOYOTA hand−held tester to the DLC3. Warm up engine to normal operating temp. CHECK: Read voltage output of heated oxygen sensor (bank 1 sensor 2) when engine suddenly raced.
  • Page 487 If the vehicle runs out of fuel, the air−fuel ratio is LEAN and DTC P0171 is recorded. The MIL then come INSPECTION PROCEDURE Check air induction system (See page SF−1). Repair or replace 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 488 Check for heated oxygen sensor (bank 1 sensor 1) data. PREPARATION: Remove the fuse cover on the instrument panel. Connect the OBD II scan tool or TOYOTA hand−held tester to the DLC3. Warm up engine to normal operating temperature. CHECK: Read the heated oxygen sensor (bank 1 sensor 1) output voltage and short−term fuel trim.
  • Page 489 Check mass air flow meter and engine coolant temp. sensor (See page SF−40, SF−61). Repair or replace. Check for spark and ignition (See page IG−1). Repair or replace. Check and replace ECM (See page IN−28). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 490 When the 2 or more codes for a misfiring cylinder are recorded repeatedly but no random misfire code is recorded, it indicates that the misfires were detected and recorded at different times. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark...
  • Page 491 With the engine idling, measure between terminals #10 − #60 and E01 of ECM. HINT: The correct waveform is as shown. (Magnification) 10V/ 10V/ Division Division 100 m sec./Division (Idling) 1 m sec./Division (Idling) Injection duration FI6588 FI6538 A00064 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 492 5 − 10 seconds at a time. Spark jumps across electrode gap. Replace or check ignition system (See page IG−1). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 493 ECM (See page IN−28). Check fuel pressure (See page SF−6). Check and repair fuel pump, pressure regulator, fuel pipe line and filter (See page SF−1). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 494 Check mass air flow meter and engine coolant temp. sensor (See page SF−40, SF−61). Repair or replace. Check engine mechanical systems compression pressure (See page EM−3), valve clearance (See page EM−4) and valve timing (See page EM−13). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 495 If the ECM detects the above DTCs, it operates the fail safe function in which the corrective retard angle value is set to the maximum value. WIRING DIAGRAM Knock Sensor 1 (On front side) KNK1 Knock Sensor 2 (On rear side) KNK2 L−W P22425 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 496 Check knock sensor (See page SF−62). Replace knock sensor. Check for open and short in harness and connector between ECM and knock sensor (See page IN−28). Repair or replace harness or connector. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 497 164 μ sec. (Normal mode vibration frequency of knock sensor: 6.1 kHz). HINT: If normal mode vibration frequency is not 6.1 kHz the sensor is malfunctioning. 200 sec./Division A00068 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 498 No crankshaft position sensor signal (NE signal) to ECM with S ECM engine speed 550 rpm or more (2 trip detection logic) WIRING DIAGRAM NE2− Distributor G− Crankshaft Position Sensor S06273 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 499 Check for open and short in harness and connector between ECM and crank- shaft position sensor for NE signal (See page IN−28). Repair or replace harness or connector. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 500 Brought to you by BirfMark DI−64 DIAGNOSTICS − ENGINE Check air gap (See page IG−1). Replace distributor housing assembly. Check and replace ECM (See page IN−28). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 501 "Hot" is from 50°C (122°F) to 100°C (212°F). Reference: INSPECTION USING OSCILLOSCOPE Refer to page DI−62 for Reference INSPECTION USING OS- CILLOSCOPE. Replace distributor housing assembly. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 502 (See page IN−28). Repair or replace harness or connector. Check air gap (See page IG−1). Replace distributor housing assembly. Check and replace ECM (See page IN−28). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 503 "Hot" is from 50°C (122°F) to 100°C (212°F). Reference: INSPECTION USING OSCILLOSCOPE Refer to page DI−62 for Reference INSPECTION USING OS- CILLOSCOPE. Replace crankshaft position sensor. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 504 Repair or replace harness or connector. Inspect sensor installation and teeth of signal plate. Tighten the sensor. Replace signal plate. Check and replace ECM (See page IN−28). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 505 (2 trip detection logic) S ECM WIRING DIAGRAM MRLY Y−R Y−R L−W VSV for EGR EGR Gas Temp. Sensor G−Y R/B No.2 BR−B From Battery P22426 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 506 (6) Start the engine and do steps (3) and (4) again. (7) Check the ”READINESS TESTS” mode on the OBD II scan tool or TOYOTA hand−held tester. If ”COMPL” is displayed and the MIL does not light up, the system is normal.
  • Page 507 − ENGINE INSPECTION PROCEDURE TOYOTA hand−held tester Connect the TOYOTA hand−held tester and read value of EGR gas temp. value. PREPARATION: Remove the fuse cover on the instrument panel. Connect the TOYOTA hand−held tester to the DLC3. Turn ignition switch ON and push the TOYOTA hand−held tester main switch ON.
  • Page 508 EGR gas temp. sensor connector is disconnected. Before checking, do a visual check and contact pressure check for the ECM connector (See page IN−28). CHECK: Read EGR gas temp. on the TOYOTA hand−held tester. EGR gas temp.: Approx. 157.5°C (315.5°F) BE6653 FI7057...
  • Page 509 ON. Select the ACTIVE TEST mode on the TOYOTA hand− held tester. CHECK: Check operation of VSV, when it is operated by the TOYOTA hand−held tester. System : OFF EGR system is ON: Air does not flow from pipe G to pipe E.
  • Page 510 Connect the TOYOTA hand−held tester to the DLC3. Turn ignition switch ON and TOYOTA hand−held tester main switch ON. Select the ACTIVE TEST mode on the TOYOTA hand−held tester. (EGR system ON) Race the engine at 4,000 rpm for 3 mins.
  • Page 511 Brought to you by BirfMark DI−75 DIAGNOSTICS − ENGINE OBD II scan tool (excluding TOYOTA hand−held tester) Check resistance of EGR gas temp. sensor. PREPARATION: Disconnect EGR gas temp. sensor connector. CHECK: Measure resistance between terminals of EGR gas temp. sen- sor connector.
  • Page 512 Repair or replace harness. Confirm connection at ECM. If OK, replace ECM (See page IN−28). Check connection of vacuum hose, EGR hose (See page EC−11). Repair or replace. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 513 (2) VSV is OFF: Air from pipe G is flows out through pipe E. (2) VSV is OFF: BE6653 P22905 Go to step 7. P22963 P22964 A00173 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 514 R/B No.2 and ECM (See page IN−28). Check EGR vacuum modulator (See page EC−11). Repair or replace. Check EGR valve (See page EC−11). Repair or replace. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 515 Resistance of EGR gas temp. sensor after 3 mins.: 4.3 kΩ or less HINT: At 20°C (68°F): 188.6 − 439.0 kΩ for resistance. Replace EGR gas temp. sensor. Check and replace ECM (See page IN−28). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 516 Read EGR gas temp. on the TOYOTA hand−held tester. EGR gas temp.: 150°C (302°F) or less (Not immediately after driving) HINT: If there is a short circuit, the TOYOTA hand−held tester indicates Approx. 157.5°C (315.5°F). Go to step 4. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 517 ENGINE Check for short in harness and ECM. PREPARATION: Disconnect the EGR gas temp. sensor connector. CHECK: EGR Gas Temp. Read EGR gas temp. on the TOYOTA hand−held tester. Sensor EGR gas temp.: 3.1°C (37.6°F) BE6653 FI7054 A00174 Replace EGR gas temp. sensor.
  • Page 518 Replace VSV for EGR. Check for short in harness and connector between VSV and ECM (See page IN−28). OBD II scan tool (excluding TOYOTA hand−held tester) Check resistance of EGR gas temp. sensor (See page DI−105). PREPARATION: Disconnect EGR gas temp. sensor connector.
  • Page 519 Check for short in harness and connector between VSV and ECM (See page IN−28). Repair or replace harness or connector. Check and replace ECM (See page IN−28). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 520 30 − 83 km/h (19 − 52 mph), the waveforms of the P0420 lyst) heated oxygen sensors, bank 1 sensor 1 and bank1 sensor 2, S Heated oxygen sensor have the same amplitude 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 521 Time A00560 (1) Connect the OBDII scan tool or TOYOTA hand−held tester to the DLC 3. (2) Start and warm up the engine with all accessories switched OFF. (3) Run the vehicle at 50 − 65 km/h (31 − 40 mph) for 5 − 10 mins.
  • Page 522 Check heated oxygen sensor (bank 1 sensor 2) (See page SF−64). Repair or replace. Replace front exhaust pipe (front catalyst) and rear TWC (rear catalyst) (See page EM−110). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 523 S Combination meter (a) Park/neutral position switch is OFF. S ECM (b) Vehicle is being driven. WIRING DIAGRAM From Cruise Control ECU Combination Meter L−W L−W P22473 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 524 Voltage is generated intermittently. 9 − 14 V Turn the wheel AT7809 Check and repair harness and connector between combination meter and ECM. Check and replace ECM (See page IN−28). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 525 S Open or short in IAC valve circuit P0505 (2 trip detection logic) S Open or short in A /C signal circuit S Air intake (hose loose) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 526 The correct waveforms are as shown. ISC3 ISC4 10 msec./Division A/C Switch ON → OFF (IAC Valve Close) ISC1 ISC2 20 V/ Division ISC3 ISC4 10 msec./Division FI6536 FI6537 A00202 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 527 Check IAC valve (See page SF−49). Replace IAC valve. Check for open and short in harness and co−nnector between EFI main relay (Marking:EFI) and IAC valve and ECM (See page IN−28). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 528 (1) The valve moves to close direction. (2) The valve moves to open direction. Open HINT: The ACTIVE TEST mode of the TOYOTA hand−held tester can be used to change the step of the IAC valve as desired. Battery P24670 Repair or replace IAC valve.
  • Page 529 S Closed throttle position switch (2 trip detection logic) S ECM HINT: After confirming DTC P0510 use the TOYOTA hand−held tester to confirm the closed throttle position switch signal from ”CURRENT DATA”. Throttle Valve Closed Throttle Position Switch Signal Malfunction...
  • Page 530 Throttle Position Connect sensor wire harness terminals between Sensor terminals 1 and 2. Turn ignition switch ON. CHECK: Read CTP switch signal on TOYOTA hand−held tester. BE6653 CTP switch signal: ON A00486 FI7058 Confirm good connection at sensor. If OK, replace throttle position sensor.
  • Page 531 Check for short in harness or ECM. PREPARATION: Disconnect throttle position sensor connector. Turn ignition switch ON. Throttle Position Sensor CHECK: Read CTP switch signal on TOYOTA hand−held tester. IDL1 CTP switch signal: OFF BE6653 A00488 A00499 Confirm good connection at sensor.
  • Page 532 Brought to you by BirfMark DI−96 DIAGNOSTICS − ENGINE OBD II scan tool (excluding TOYOTA hand−held tester) Check for open and short in harness or ECM. PREPARATION: Disconnect throttle position sensor connector. Throttle Position Sensor Turn ignition switch ON. CHECK: Measure voltage between terminals 1 and 2 of throttle position sensor connector.
  • Page 533 S Igniter engine running S ECM WIRING DIAGRAM B−R IG Switch Distributor B−W B−W Fusible B−G B−G Link W−B B−Y B−Y Noise Filter Igniter Ignition Battery Coil P22475 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 534 Measure voltage between terminal IGF of ECM connector and body ground. (−) BE6653 P24673 A00183 Voltage: 4.5 − 5.5 V Replace igniter. Check and replace ECM (See page IN−28). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 535 IGT and E1 of engine control module. HINT: The correct regulator waveforms are as shown. 5 m sec/Division (Idling) FI6605 Check and replace ECM (See page IN−28). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 536 Check for open and short in harness and connector between ignition switch and ignition coil, ignition coil and igniter (See page IN−28). Repair or replace harness or connector. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 537 Brought to you by BirfMark DI−101 DIAGNOSTICS − ENGINE Check ignition coil (See page IG−1). Replace ignition coil. Replace igniter. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 538 1,000 rpm or more S Starter S ECM WIRING DIAGRAM See DTC P0335 (Crankshaft Position Sensor ”A” Circuit Malfunction) for WIRING DIAGRAM and INSPEC- TION PROCEDURE. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 539 STA of the ECM. The starter signal is mainly used to increase the fuel injection volume for the starting injection control and after−start injection control. WIRING DIAGRAM A15825 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 540 Connect TOYOTA hand−held tester and check STA signal. PREPARATION: Connect the TOYOTA hand−held tester to the DLC3. Turn ignition switch ON and push TOYOTA hand−held tester main switch ON. CHECK: Read STA signal on the TOYOTA hand−held tester while starter operates.
  • Page 541 Open in back up power source circuit S ECM HINT: If DTC P1600 appear, the ECM does not store another DTC. WIRING DIAGRAM R/B No.2 BATT R−Y R−Y Fusible Link Battery P22477 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 542 EFI Fuse P22346 Check for short in all the harness and components connected to EFI fuse. Check and repair harness or connector between battery, EFI fuse and ECM. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 543 Refer to P0325, P0330 (Knock Sensor 1, 2 Circuit Malfunction) on page DI−59. INSPECTION PROCEDURE Are there any other codes (besides DTC P1605) being output? Go to relevant DTC chart. Check and replace ECM (See page IN−28). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 544 (2 trip detection logic) (a) Vehicle speed: 70 km/h (44 mph) or more (b) Engine speed: 1,500 − 2,500 rpm HINT: After confirming DTC P1780 use the TOYOTA hand−held tester to confirm the PNP switch signal from ”CUR- RENT DATA”. WIRING DIAGRAM Park/Neutral...
  • Page 545 9 − 14 V Check and replace ECM (See page IN−28). Check for open and short in harness and connector between ECM and park/neutral position switch (See page IN−28). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 546 EFI main relay (Marking: EFI) and supplying power to the terminals +B of the ECM. WIRING DIAGRAM W−R 11 B−R B−L IGSW R −Y IG Switch Fuse Block Y−R MRLY EFI Main Relay R/B No.2 Fusible Y−R Link BR−B Battery S00816 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 547 Turn ignition switch ON. CHECK: Measure voltage between terminals IGSW of ECM and body ground. IGSW (−) BE6653 Voltage: 9 − 14 V P24680 A00190 Go to step 6. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 548 1 − 2 − 4 5 − 6 − 11 Replace ignition switch. Check for open and short in harness and connector between battery and ignition switch and ECM. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 549 Check for short in all the harness and components connected to EFI fuse. Check EFI main relay (Marking: EFI) (See page SF−54). Replace EFI main relay (Marking: EFI). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 550 ECM connector and body ground (See page IN−28). Repair or replace harness or connector. Check for open and short in harness and connector between terminal +B of ECM connector and battery (See page IN−28). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 551 Fuel Pump Relay IG Switch Fuel Pump Resistor Park/ N eut ra l Position Switch Fuel Pump (STA Signal) Battery (NE Signal) From Crankshaft Position Sensor Starter P22480 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 552 Relay R−G R−W R−W B−L B−R IG Switch Fuse Block Fuel Pump Relay R−B W−R R−B R−G Fusible Fuel Pump Link Resister W−B Battery Fuel Pump S02978 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 553 − ENGINE INSPECTION PROCEDURE TOYOTA hand−held tester Connect the TOYOTA hand−held tester and check operation of fuel pump. PREPARATION: Remove the fuse cover on the instrument panel. Connect the TOYOTA hand−held tester to the DLC3. Turn ignition switch ON and TOYOTA hand−held tester main switch ON.
  • Page 554 Select the ACTIVE TEST mode on the TOYOTA hand−held tester. CHECK: Check operation of fuel pump relay when it is switched ON and OFF by the TOYOTA hand−held tester. Operating noise can be heard from the relay. Go to step 8.
  • Page 555 Time after engine started Voltage 60 seconds or more 0 − 3 V Less than 60 seconds 9 − 14 V Check and replace ECM (See page IN−28). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 556 PREPARATION: Remove instrument panel speaker No.1 panel (See page SF−65). Connect the TOYOTA hand − held tester to the DLC3. Turn ignition switch ON and TOYOTA hand−held tester main switch ON. Use ACTIVE TEST mode to operate the fuel pump.
  • Page 557 Replace fuel pump resistor. Check for open and short in harness and connector between fuel pump relay and fuel pump resis- tor and fuel pump (See page IN−28). OBD II scan tool (excluding TOYOTA hand−held tester) Check fuel pump operation. PREPARATION: Remove instrument panel speaker No.1 panel (See page...
  • Page 558 Check for open and short in harness and connector between terminal FC of ECM and circuit open- ing relay and fuse block (See page IN−28). Check operation of fuel pump relay (See step 5 of TOYOTA hand−held tester). Replace fuel pump relay.
  • Page 559 Check for open or short in harness and connector between EFI main relay (Marking: EFI) and cir- cuit opening relay and fuel pump relay and fuel pump and body ground (See page IN−28). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark...
  • Page 560 Replace fuel pump resistor. Check for open and short in harness and connector between fuel pump relay and fuel pump resis- tor and fuel pump (See page IN−28). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 561 Fuel pressure control ends approx. 120 sec. after the engine is P22216 started. WIRING DIAGRAM MRLY Y−R Y−R R/B No.2 L−R VSV for Fuel Pressure Control From Battery P22482 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 562 DIAGNOSTICS − ENGINE INSPECTION PROCEDURE TOYOTA hand−held tester Connect the TOYOTA hand−held tester and check operation of VSV for fuel pressure control. PREPARATION: Remove the fuse cover on the instrument panel. Connect the TOYOTA hand−held tester to the DLC3. Turn ignition switch ON and TOYOTA hand−held tester main switch ON.
  • Page 563 (Marking: EFI) and ECM (See page IN−28). Repair or replace harness or connector. Check and replace ECM (See page IN−28). OBD II scan tool (excluding TOYOTA hand−held tester) Check VSV for fuel pressure control (See page SF−59). Replace VSV for fuel pressure control.
  • Page 564 Brought to you by BirfMark DI−128 DIAGNOSTICS − ENGINE Check fuel pressure regulator (See page SF−19). Repair or replace fuel pressure regulator. Check and replace ECM (See page IN−28). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...

  • Page 565: Automatic Transmission

    Diagnostic steps permitting the use of the TOYOTA DI−130 hand−held tester or TOYOTA brake−out−box. Connect an OBD II scan tool or TOYOTA hand−held tester to DLC3. If your display shows ”UNABLE TO CONNECT TO VEHICLE” when you have connected the DI−131 scan tool/TOYOTA hand−held tester, inspect DLC3...
  • Page 566 Normal j Remains ON Indicator Lamp 1st Time j Normal code j Malfunction code (Code DTC Check 2nd Time j Normal code j Malfunction code (Code 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 567 To check the DTCs, connect an OBD II scan tool or TOYOTA Hand−held Tester TOYOTA hand−held tester to the DLC3 on the ve- hicle. The OBD II scan tool or TOYOTA hand−held tester also enables you to erase the DTCs and...
  • Page 568 Prepare the OBD II scan tool (complying with SAE TOYOTA Hand−held Tester J1978) or TOYOTA hand−held tester. Connect the OBD II scan tool or TOYOTA hand− held tester to the DLC3 in the fuse box at the lower left of the instrument panel.
  • Page 569 Brought to you by BirfMark DI−133 DIAGNOSTICS − AUTOMATIC TRANSMISSION Use the OBD II scan tool or TOYOTA hand−held tester to check the DTCs and freeze frame data. Note them down (For operating instructions, see the OBD II scan tool’s instruction book). See page DI−143...
  • Page 570 (See the OBD II scan tool’s instruction book for operating instructions.). NOTICE: If the TOYOTA hand−held tester switches the ECM from the normal mode to the check mode or vice−versa, or if the ignition switch is turned from ON to ACC or OFF during the check mode, the DTCs and freezed frame data will be erased.
  • Page 571 If your display shows ”UNABLE TO CONNECT TO VEHICLE” when you have connected the cable of the OBD II scan tool or TOYOTA hand−held tester to the DLC3, turned the ignition switch ON and operated the scan tool, there is a problem on the vehicle side or tool side.
  • Page 572 1stand reverse brake is defective. Check for abnormal noise during acceleration and deceleration. R position test. Shift into the R position and fully depress the accelerator pedal and check for slipping. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 573 If the fluid smells burnt or is black, replace it. Replace the ATF. Remove the drain plug and drain the ATF. Reinstall the drain plug securely. Q07273 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 574 If the indicator is not aligned with the correct position, carry out the following adjustment procedures. Loosen the nut on the control rod. Push the control rod fully rearward. Q07309 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 575 Chock the 4 wheels. Connect an OBD II scan tool or TOYOTA hand−held tester to the DLC3. Fully apply the parking brake. Keep your left foot pressed firmly on the brake pedal.
  • Page 576 S Line pressure too low S Direct clutch worn N → R time lag is longer S 1st and reverse brake worn S O/D one−way clutch not operating properly 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 577 S Forward clutch defective S R position circuit fluid leakage If pressure is low in the R position only S Direct clutch defective S 1st and reverse brake defective 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 578 Connect the solenoid wire connector. Clear DTCs. HINT: When the solenoid wire is disconnected, the transmission gear will be set as listed below: Shift Lever Gear Parking Reverse Neutral O/D (4th) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 579 (No. 2 Vehicle Speed Sensor) S ECM S Short in park/neutral position switch circuit P1780 Park/Neutral Position Switch S Park/neutral position switch (DI−169) Malfunction S ECM ...MIL light up 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 580 Speed Sensor No. 2 Vehicle Speed Sensor Shift Solenoid Valve No. 2 Park/Neutral Position Switch Shift Solenoid Valve No. 1 Shift Solenoid Valve SL Stop Light Switch Q08236 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 581 Below 1.5 IG ON Accel. pedal is released Below 1.5 IDL (E5−11) − E2 (E5−9) G−W − BR−B IG ON Accel. pedal is depressed 9 − 14 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 582 HOLD (E4−3) − E1 (E4−24) O − BR−B IG ON 2nd start switch OFF Below 1.5 HI (E4−18) − E1 (E4−24) R−W − BR−B IG ON 7.5 − 14 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 583 DI−169 7. O/D cancel signal circuit DI−172 8. Engine coolant temp. sensor circuit DI−30 9. On−vehicle repair matrix chart − 10.Off−vehicle repair matrix chart − 11.ECM DI−145 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 584 1. Engine coolant temp. sensor circuit DI−30 2. On−vehicle repair matrix chart − Up−shift to O/D from 3rd while engine is cold 3. Off−vehicle repair matrix chart − 4. ECM DI−145 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 585 DI−163 2. Stop light switch circuit DI−185 Large shift shock or engine stalls when starting off or stopping 3. Off−vehicle repair matrix chart − 4. ECM DI−145 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 586 2. B accumulator 3. Off−vehicle repair matrix chart − 1. Accumulator control valve Harsh engagement (O/D → 3rd) 2. C accumulator 3. Off−vehicle repair matrix chart − 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 587 Slip or shudder (Forward and reverse (After warm−up)) 2. O/D one−way clutch (F 3. O/D direct clutch (C Slip or shudder (Forward and reverse (Just after engine starts)) 1. Torque converter clutch AT−26 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 588 Poor acceleration (L and R positions) 1. 1st and reverse brake (B Poor acceleration (R position) 1. Forward clutch (C Engine stalls when starting off or stopping 1. Torque converter clutch AT−26 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 589 Brought to you by BirfMark DI−153 DIAGNOSTICS − AUTOMATIC TRANSMISSION DI5KI−01 CIRCUIT INSPECTION P0500 Vehicle Speed Sensor Malfunction (No. 1 Vehicle Speed Sensor) See page DI−87. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 590 (b) After the engine has been operating for 15 min. or more, the S ECM resistance at the temp. sensor is more than 156 kΩ WIRING DIAGRAM 4 − 6 V ATF Temperature Sensor R−W BR−B Q04346 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 591 Replace ATF temperature sensor. Check harness and connector between ATF temperature sensor and ECM (See page IN−28). Repair or replace harness or connector. Check and replace ECM. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...

  • Page 592: System Description

    D00081 Q08221 Replace shift solenoid valve No. 1 or No. 2. Check valve body (See page DI−147). Repair or replace valve body. Repair transmission (See page AT−18). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 593 (a) Solenoid resistance is 8 Ω or less (short circuit) when the solenoid is energized (b) Solenoid resistance is 100 kΩ or more (open circuit) when the solenoid is not energized 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 594 Disconnect the connector from the ECM. CHECK: Measure the resistance between terminal S1 or S2 of the ECM and body ground. Resistance: 11 − 15 Ω Q07641 Check and replace ECM. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 595 ECM and S1 or S2 terminals of the solenoid connector. There is no open and no short circuit. Q07643 Q07312 D00082 Repair or replace harness or connector. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 596 (b) The shift solenoid valve No. 1 or No. 2 makes an operating noise. Replace shift solenoid valve No. 1 or No. 2. Repair or replace solenoid wire. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 597 When battery voltage is supplied to the shift solenoid valve, check it does not leak air. (−) Q08219 D00087 Q08226 Replace shift solenoid valve SL. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 598 Brought to you by BirfMark DI−162 DIAGNOSTICS − AUTOMATIC TRANSMISSION Check valve body (See page DI−147). Repair or replace valve body. Replace torque converter clutch (See page AT−26). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 599 Open or short in shift solenoid valve SL circuit for 1 time P0773 S Shift solenoid valve SL (2 trip detection logic) S ECM WIRING DIAGRAM Transmission Solenoid Valve SL R−L R−L Q07464 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 600 Check the harness between terminal SL of the ECM and termi- nal SL of the automatic transmission solenoid connector. There is no open or short circuit. Q07649 D00088 Q07312 Repair or replace harness or connector. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 601 lead to the solenoid body. (a) Resistance: 11 − 15 Ω (b) Shift solenoid valve SL makes operation noise. Replace shift solenoid valve SL. Check and replace or repair solenoid wire. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 602 (d) Transfer position: Other than N position Reference: − Waveform between terminals SP2 and SP2 when the vehicle speed is approx. 60 km/h (37 mph). 5 V/div. 2 msec./div. AT8761 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 603 Remove the fuse box cover. Connect an OBD II scan tool or TOYOTA hand−held tes- ter to the DLC3. Start the engine and turn the OBD II scan tool or TOYOTA hand−held tester main switch ON. CHECK: Drive the vehicle and read vehicle speed value.
  • Page 604 The generated voltage is extremely low. D00179 Q08218 Replace No. 2 vehicle speed sensor. Check and repair harness and connector be- tween ECM and No. 2 vehicle speed sensor (See page IN−28). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 605 B−L Park/Neutral R−B G−W Position Switch R/B No. 2 G−W G−R Fuse Block Ignition Switch R−B R−B B−Y B−W B−W B−R From Starter Battery B−W Q08577 D00180 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 606 Turn the ignition switch ON and TOYOTA hand−held tes- ter main switch ON. CHECK: Shift lever into the P, R, N, 2 and L positions, and read the PNP, REVERSE, 2 and L signals on the TOYOTA hand−held tester. Shift position Signal 2ND OFF → ON LOW OFF →...
  • Page 607 3 − 4 − Replace park/neutral position switch. Repair or replace harness and connector between battery and park/neutral position switch, and park/neutral position switch and ECM (See page IN−28). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 608 Measure the voltage between terminal OD1 of the ECM and body ground. Voltage: 9 − 14 V (−) BE3840 D00091 Q07658 Proceed to next circuit inspection shown on problem symptoms table (See page DI−147). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 609 Check and replace cruise control ECU. Check harness and connector between cruise control ECU and ECM (See page IN−28). Repair or replace wire harness or connector. Check and replace ECM. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 610 R/B No. 2 Fuse Block FL AM1 B−L W−B Battery O/D Main switch Contact go off with switch pushed in. Contact go on with switch once again. Q08582 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 611 Check the O/D OFF indicator light when the O/D main switch is pushed again to OFF. O/D OFF indicator light lights up BE3840 D00092 D00077 Go to step 4. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 612 Connect a TOYOTA hand−held tester to the DLC3. Turn the ignition switch ON and TOYOTA hand−held tes- ter main switch ON. CHECK: Read the OVRDRIVE CUT SW2 signal on the TOYOTA hand− held tester. O/D Main Switch OVRDRIVE CUT SW2 Signal...
  • Page 613 Measure the resistance between terminals 2 and 4 of the O/D main switch connector. O/D Main Switch Resistance ∞ Ω 〈open) 0 Ω (continuity) Q08233 Replace O/D main switch. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 614 Check harness and connector between O/D OFF indicator light and O/D main switch, and O/D OFF indicator light and ECM (See page IN−28). Repair or replace harness or connector. Check and replace ECM. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 615 Check operation of PWR indicator light. PREPARATION: Check if the PWR indicator light normally when the PWR mode switch is set to NORM and PWR position. Check and repair PWR indicator light. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 616 When using TOYOTA hand−held tester: PREPARATION: Remove the fuse box cover. Connect a TOYOTA hand−held tester to the DLC3. Turn the ignition switch ON and TOYOTA hand−held tes- ter main switch ON. CHECK: Read the PWR signal on the TOYOTA hand−held tester.
  • Page 617 Check harness and connector between battery and pattern select switch, and pattern select switch and ECM (See page IN−28). Repair or replace harness or connector. Check and replace ECM. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 618 To cancel the 2nd start, push the 2nd start swtch once again. The 2nd start is automatically cancelled out when the ignition switch is turned OFF. Q08580 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 619 ”PWR” indicator light lights up. Proceed to next circuit inspection shown on problem symptoms table (See page DI−147). Check 2nd start indicator bulb. Replace 2nd start indicator bulb. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 620 Check and replace harness and connector between battery and patten select switch, pattern se- lect switch and ECM, battery and 2nd start indicator light, and 2nd start indicator light and ECM (See page IN−28). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 621 When the 2nd start switch is pushed, the switch is contacted and the 2nd mode is selected. To cancel the 2nd start, push the 2nd start switch once again. The 2nd start is automatically cancelled out when the ignition switch is turned OFF. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 622 ”PWR” indicator light lights up. Proceed to next circuit inspection shown on matrix chart (See page DI-150 Check 2nd start indicator bulb. Replace 2nd start indicator bulb. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 623 Check and replace harness and connector between battery and patten select switch, pattern se- lect switch and ECM, battery and 2nd start indicator light , 2nd start indicator light and ECM (See page IN-27 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 624 − DI−235 Identification of Problem Repair Confirmation Test Step 8: Diagnostic steps permitting the use of the TOYOTA hand−held tester or TOYOTA breake−out−box. 1996 LAND CRUISER (RM451U) Author : Date : Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 625 ABS does not operate efficiently. ABS Warning Light Remains ON Does not Light Up Abnormal Normal Code Malfunction Code (Code 1st Time DTC Check Normal Code Malfunction Code (Code 2nd Time 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 626 Read the DTC from the ABS warning light on the combination meter. HINT: If no code appears, inspect the diagnostic circuit or ABS DLC1 warning light circuit (See page DI−233 or DI−230). F00007 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 627 Connect the short pin to the DLC1. HINT: Cancellation can also be done by removing the ECU−B fuse, but in this case, other memory systems will also be cancelled out. DLC1 F00006 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 628 TA break−out−box to the vehicle. Read the ECU input/output values by following the prompts on the tester screen. HINT: TOYOTA hand−held tester has a ”Snapshot ” function. This re- TOYOTA Break−out−box cords the measured values and is effective in the diagnosis of N09348 intermittent problems.
  • Page 629 If the warning light turns on, inspect the deceleration sensor installation. If the sensor installation is OK, replace the decel- 860 " 30 mm eration sensor. 33.86 " 1.18 in. Jack down the vehicle slowly. R05037 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 630 If the sensor installation is OK, replace the de- celeration sensor. Stop the vehicle and turn the ignition switch OFF. Braking Remove SST from the terminals Ts and E of the DLC1. 09843−18020 R05597 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 631 S Left rear speed sensor rotor Abnormal change in output voltage of left rear speed sensor S Sensor wire harness S Deceleration sensor Deceleration sensor is faulty S Sensor installation 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 632 S Open or short in deceleration sensor circuit Open or short circuit in center differential lock circuit S Center differential lock (DI−221) Center differential is locking S Center differential lock circuit 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 633 Open in pump motor ground S Battery Always ON Malfunction in ECU S IC regulator (DI−225) IG power source circuit S Open or short in power source circuit S ECU 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 634 ABS Warning Light Deceleration Sensor DLC1 ABS Relay Front Speed Sensor Rear Speed Sensor Rotor ABS ECU Stop Light Switch ABS Actuator Front Speed Sensor Rotor W03004 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 635 1. ABS warning light circuit DI−230 2. Tc terminal circuit DI−233 Speed sensor signal check 1. Ts terminal circuit DI−235 cannot be done 2. ABS ECU − 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 636 Relay R− G−Y No. 2 B−W Solenoid W−B 12 V Relay G−B DLC1 B−R B−L No. 2 ABS ECU L−Y W−B L−W W−B Battery ABS Actuator W02192 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 637 Continuity HINT: Actuator There is a resistance of 4 ∼ 6 Ω between terminals A4−4 and A5−2. ABS ECU R00888 Repair or replace harness or ABS actuator. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 638 Repair or replace harness or connector. If same code is still output after DTC is deleted, check contact condition of each connection. If connections are normal, ECU may be defective. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 639 SRR is 0 V or battery positive voltage Fail safe function: If trouble occurs in the actuator solenoid circuit, the ECU cuts off current to the ABS control (solenoid) relay and prohibits ABS control. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 640 Check the continuity between terminals A4 − 4 and A5−1, 3, 4 of the ABS actuator connector. Continuity HINT: Resistance of each solenoid coil is 0.8 − 1.6 Ω F00026 Replace ABS actuator. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 641 Repair or replace harness or connector. If same code is still output after DTC is deleted, check contact condition of each connection. If connector are normal, ECU may be defective. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 642 DTC No. 34 is for the left rear speed sensor. Fail safe function: If trouble occurs in the speed sensor circuit, the ECU cuts off current to the ABS control (solenoid) relay and prohibits ABS control. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 643 DI-211 DIAGNOSTICS ANTI-LOCK BRAKE SYSTEM WIRING DIAGRAM ABS ECU Left Front Speed Sensor Right Front Speed Sensor Left Rear BR-B Speed Sensor Right Rear Speed Sensor W02194 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 644 Measure resistance between terminals 1 and 2 of speed sensor W02207 W02208 connector and body ground. F00036 Resistance: 1 MΩ or higher Replace speed sensor. NOTICE: Check the speed sensor signal last (See page DI-189 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 645 Drive the vehicle at 30 km/h (19 mph), and check the signal wa- veform. 2 ms/Division W04200 Turn the IG swithch OFF, check and replace ABS ECU. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 646 Replace speed sensor or rotor. BR3795 NOTICE: Check the speed sensor signal last (See page DI-189 Check and replace ABS ECU. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 647 ABS control. WIRING DIAGRAM ABS ECU Ignition Switch ECU−IG B−W B−Y B−W Junction Connector R/B No. 2 Deceleration Sensor R/B No. 2 B−L F6 1 Battery W02195 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 648 Measure the resistance between terminal GND of the ABS ECU connector and body ground. Resistance: 1 Ω or less BE6653 F00035 R14208 Repair or replace harness or connector. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 649 Check for short in all harness and components connected to ECU−IG fuse (See attached wiring diagram). Check for open in harness and connector be- (See page tween ABS ECU and battery IN−28 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 650 Check for open or short in harness and connector between sensor and ECU (See page IN−28). Repair or replace harness and connector. Check and replace ABS ECU. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 651 During this time, a trouble signal is detected for 0.5 sec. WIRING DIAGRAM ABS ECU ABS ECU B−W B−W B−W 12 V Junction Connector Y−B Y−B Deceleration 12 V Sensor Y−R Y−R ECU−IG W−B W02196 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 652 GS1, GS2: 4 − 14 V GST: As shown below IG SW 1.5 sec. 0.5 sec. F00012 Check and replace ABS ECU. Check and replace deceleration sensor. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 653 P−B CENTER DIFF. LOCK DETECTION Battery Switch W02197 INSPECTION PROCEDURE Check the center differential is free (Transfer is in H position). Repair the center differential lock system. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 654 Check for open in harness and connector between battery and CENTER DIFF. LOCK indicator light, and CENTER DIFF. LOCK indicator light and ABS ECU (See page IN−28). Repair or replace harness or connector. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 655 Check for short in harness and connector between CENTER DIFF. LOCK indica- tor light and ABS ECU (See page IN−28). Repair or replace harness or connector. Check and replace ABS ECU. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 656 Relay R− G−Y No. 2 B−W Solenoid W−B 12 V Relay G−B DLC1 B−L B−R No. 2 ABS ECU L−Y W−B L−W W−B Battery ABS Actuator W02192 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 657 ABS control. WIRING DIAGRAM ABS ECU Ignition Switch ECU−IG B−W B−Y B−W Junction Connector R/B No. 2 Deceleration Sensor R/B No. 2 B−L F6 1 Battery W02195 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 658 ECU−IG fuse and ECU (See page IN−28). Check battery positive voltage. PREPARATION: Start the engine. CHECK: Check the battery positive voltage. Voltage: 10 − 16 V Check and repair charging system. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 659 Check and replace ABS ECU. Check for short in harness and connector between combination meter and ABS ECU, and com- bination meter and DLC1 (See page IN−28). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 660 CHECK: Check that stop light lights up when brake pedal is depressed and turns off when brake pedal is released. Repair stop light circuit (See page BE−24). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 661 Check for open in harness and connector between ABS ECU and stop light switch (See page IN−28). Repair or replace harness or connector. Check and replace ABS ECU. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 662 Go to step 1 ABS warning light remains on Go to step 3 Check ABS warning light. See Combination Meter Troubleshooting on page BE−2. Repair bulb or combination meter assembly. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 663 A7−5. Recheck continuity between terminals. R14144 Replace ABS control relay. Check for open in harness and connector be- tween DLC1 and ABS control relay and body ground (See page IN−28). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 664 Check ABS control relay (See step 2). Replace ABS control relay. Check for short in harness and connector be- tween DLC1 and ABS control relay (See page IN−28). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 665 DLC1. Voltage: 10 − 14 V DLC1 F00007 If ABS warning light does not blink even after Tc and E are connected, ECU may be defective. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 666 Check for open and short in harness and connector between ABS ECU and DLC1, and DLC1 and body ground (See page IN−28). Repair or replace harness or connector. Check and replace ABS ECU. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 667 DLC1. Voltage: 10 − 14 V DLC1 F00007 If ABS warning light does not blink even after Ts and E are connected, ECU may be defective. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 668 Check for open and short in harness and connector between ABS ECU and DLC1, and DLC1 and body ground (See page IN−28). Repair or replace harness or connector. Check and replace ABS ECU. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 669 Brought to you by BirfMark DI−237 DIAGNOSTICS − ANTI−LOCK BRAKE SYSTEM DI5MP−02 Check for Fluid Leakage Check for fluid leakage from actuator or hydraulic lines. W02202 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...

  • Page 670: Supplemental Restraint System

    DI−240 Normal Code Confirmation Test : Diagnostic steps permitting the use Step 3, 4, 5, 10, 11, 12 of the TOYOTA hand−held tester. 1996 LAND CRUISER (RM451U) Author : Date : Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 671 Remains ON Sometimes Light Up Does Not Light Up 1st Time Normal Code Malfunction Code [ Code. DTC Inspection 2nd Time Normal Code Malfunction Code [ Code. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 672 The first blinking output indicates the first digit AT0716 of a 2−digit DTC. After a 1.5 second pause, the second blinking output will indicate the second digit. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 673 Code 11 tion on page DI−279. AB0056 DTC CHECK (Using TOYOTA hand−held tester) Hook up the TOYOTA hand−held tester to the DLC1. Read the DTCs by following the prompts on the tester screen. HINT: Please refer to the TOYOTA hand−held tester operator’s manu- al, for further details.
  • Page 674 SRS waring light will blink in a 50 m sec. cycle to indicate the codes have been cleared. USING TOYOTA HAND−HELD TESTER Hook up the TOYOTA hand−held tester to the DLC1. Clear the DTC by following the prompts on the tester screen.
  • Page 675 When 2 or more codes are indicated, the codes will be displayed in numeral order starting from the lowest numbered code. If a code not listed on the chart is displayed, the airbag sensor assembly is faulty. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 676 Brought to you by BirfMark DI−244 DIAGNOSTICS − SUPPLEMENTAL RESTRAINT SYSTEM DI5Q4−02 PARTS LOCATION Front Passenger Airbag Assembly Steering Wheel Pad (With Airbag) Spiral Cable Airbag Sensor Assembly R13515 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 677 Electrical Connection Check Mechanism − Squib (Passenger) Squib (Passenger) − Squib (Driver) Squib (Driver) Ground Ground Diagnosis SRS Warning Light Power Source (IGN Fuse) Power Source (CIG Fuse) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 678 S SRS warning light is always lit up with a DTC check procedure. S Tc terminal circuit DI−279 S DTC displayed without Tc and E1 terminal connection. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 679 S Airbag sensor assembly S Airbag sensor assembly malfunction S Wire harness WIRING DIAGRAM Airbag Sensor Assembly W−R P Squib B−R − D Squib − Spiral Cable R16017 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 680 − and body ground. Spiral Resistance: 1 MΩ or Higher Cable D Squib D− R05901 R14290 H00004 Go to step 7. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 681 Assembly P Squib Spiral Cable D Squib Repair or replace harness or connector be- R14291 R05896 H00005 tween the airbag sensor assembly and front passenger airbag assembly. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 682 R13006 W02042 H00006 HINT: Codes other than code 11 may be output at this time, but they are not relevant to this check. Replace airbag sensor assembly. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 683 DTC 11 is not output. HINT: Codes other than code 11 may be output at this time, but they are not relevant to this check. Replace steering wheel pad. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 684 Replace front passenger airbag assembly. From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 685 Resistance: 1 MΩ or Higher Repair or replace spiral cable. R05899 H00009 R14301 Repair or replace harness or connector be- tween airbag sensor assembly and spiral cable. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 686 Assembly P Squib − and body ground. Voltage: 0 V Spiral Cable D Squib D− (−) AB0119 W01931 Go to step 7. R14300 H00010 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 687 P Squib D Squib Spiral Cable AB0119 Repair or replace harness or connector be- R05898 H00011 tween the airbag sensor assembly and front R14300 passenger airbag assembly. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 688 W02043 R13006 H00012 HINT: Codes other than code 12 may be output at this time, but they are not relevant to this check. Replace airbag sensor assembly. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 689 DTC 12 is not output. HINT: Codes other than code 12 may be output at this time, but they are not relevant to this check. Replace steering wheel pad. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 690 Replace front passenger airbag assembly. From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 691 Voltage: 0 V (−) R05899 Repair or replace spiral cable. AB0119 H00015 R14288 Repair or replace harness or connector between airbag sensor assembly and spiral cable. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 692 S Wire harness S Center airbag sensor assembly malfunction WIRING DIAGRAM Airbag Sensor Assembly D Squib − Spiral Cable R15194 INSPECTION PROCEDURE Preparation. (See step 1 on page DI−271) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 693 D Squib − and D Resistance: Below 1 Ω D− D− Go to step 5. W02055 R14286 R12688 H00016 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 694 DTC 14 is not output. HINT: Codes other than code 14 may be output at this time, but they are not relevant to this check. Replace airbag sensor assembly. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 695 Replace steering wheel pad. From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 696 R14286 R12688 From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 697 Measure voltage between terminals IG2 and ACC of airbag sensor assembly and body ground. (−) Voltage: Below 16 V Check battery and charging system (See page AB0119 H00021 R14285 CH−2). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 698 Using SST, connect terminals Tc and E1 of DLC 1. 09843−18020 Check the DTC. Using simulation method, reproduce malfunc- AB0119 AB0118 R13006 FI1394 H00022 tion symptoms (See page IN−18). Replace airbag sensor assembly. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 699 S Airbag sensor assembly S Squib malfunction S Wire harness S Airbag sensor assembly malfunction WIRING DIAGRAM Airbag Sensor Assembly W−R P Squib B−R − R15195 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 700 Cable Airbag Sensor D Squib Assembly R12689 R14287 W01936 H00023 Repair or replace harness or connector be- tween airbag sensor assembly and front pas- senger airbag assembly. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 701 Codes other than code 54 may be output at this time, but they AB0069 W01934 AB0119 are not relevant to this check. AB0118 W02045 H00024 R13006 Replace airbag sensor assembly. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 702 Replace front passenger airbag assembly. From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 703 Normal Source voltage dorp S Airbag sensor assembly WIRING DIAGRAM L−R J3 Junction Connector B−L B−R B−W W−R Short Connector Ignition Switch Airbag Sensor Assembly Battery R13678 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 704 (defogger, wiper, headlight, heater blower, etc.) (−) Voltage: 10 − 14 V AB0119 H00021 R14285 Check the harness between battery and airbag sensor assembly, and check the battery and charging system. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 705 From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 706 Airbag Sensor Assembly SRS Warning Light W−L B−R 2 W−L ECU−B Short Connector B−L B−Y GENERATOR (ALTERNATOR) Short Connector FL BLOCK Cruise Control ECU Battery DLC1 R13679 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 707 Connect negative (−) terminal cable to battery. CHECK: Check operation of SRS warning light. AB0117 N12639 H00026 Check SRS warning light circuit or terminal AB circuit of DLC1. Replace airbag sensor assembly. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 708 Fuse may be burnt out even if it appears to be OK during visual inspection. N14677 If fuse is OK, install it. Go to step 5. Preparation. (See step 1 on page DI−271) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 709 H00051 From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 710 SUPPLEMENTAL RESTRAINT SYSTEM Is new ECU−B fuse burnt out again? Using simulation method, reproduce malfunc- tion symptoms (See page IN−18). Check harness between ECU−B fuse and SRS warning light. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 711 By connecting terminals Tc and E1 of the DLC1 the airbag sensor assembly is set in the DTC output mode. The DTCs are displayed by the blinking of the SRS warning light. WIRING DIAGRAM Airbag Sensor Assembly 7 B−L B−Y B−Y BR−B Short Connector DLC1 R13680 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 712 Turn ignition switch to ACC or ON. CHECK: Measure voltage between terminals Tc and E1 of DLC1. DLC1 Voltage: 10 − 14 V (−) AB0118 AB0119 H00030 R14305 Go to step 4. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 713 Measure voltage between terminals Tc of DLC1 and body ground. Voltage: 10 − 14 V (−) Check harness between terminal E1 of DLC1 AB0118 AB0119 H00031 R14304 and body ground. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 714 Never make a mistake with the terminal connection posi- tion as this will cause a malfunction. Check harness between airbag sensor assem- bly and DLC1. Replace airbag sensor assembly. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 715 Check resistance between terminal Tc of airbag sensor assem- bly connector and body ground. AB0117 R14303 H00033 Resistance: 1 MΩ or Higher Repair or replace harness or connector. Replace airbag sensor assembly. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...

  • Page 716: Cruise Control System

    − DI−310 Identification of Problem Repair Confirmation Test Step 2, 5, 8, 10: Diagnostic steps permitting the use of the TOYOTA hand−held tester or TOYOTA break−out−box. 1996 LAND CRUISER (RM451U) Author : Date : Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 717 Does not light up j Blinking indicator light 1st Time j Normal Code j Malfunction Code (Code DTC Check 2nd Time j Normal Code j Malfunction Code (Code 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 718 Does not light up j Blinking indicator light 1st Time j Normal Code j Malfunction Code (Code DTC Check 2nd Time j Normal Code j Malfunction Code (Code 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 719 Output of DTC using diagnosis check wire. DLC1 Turn the ignition switch ON. Using SST, connect terminals Tc and E of DLC1. 09843-18020 Read the DTC on the CRUISE MAIN indicator light. N06219 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 720 ECU TERMINAL VALUES MEASUREMENT BY USING TOYOTA hand-held tester TOYOTA BREAK-OUT-BOX AND TOYOTA HAND- HELD TESTER Hook up the TOYOTA break- out- box and TOYOTA hand-held tester to the vehicle. Read the ECU input/output values by following the prompts on the tester screen.
  • Page 721 Momentarily press the control switch is turned to N14305 SET/COAST, and then immediately release it. Check that the vehicle speed decreases by about 1.5 km/h (Tap-down function). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 722 After the control switch is turned to RES/ACC at the driving speed of more than 40 km/h (25 mph), check that the vehicle restores the speed prior to the can- cellation. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 723 Switch OFF normal Light ON Drive at about 40 km/h (25 mph)or higher Vehicle Speed Sensor is normal Drive at about 40 km/h Light (25 mph) or below 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 724 S Harness or connector between cruise control ECU and cruise S Control Switch Circuit (DI−311) control switch, cruise control switch and body ground S Cruise control ECU 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 725  Control Switch Stop Light Switch Instrument Panel Fuse Block  GAUGE Fuse  ECU−IG Fuse  ECU−B Fuse No.1 Vehicle Speed Sensor Park/Neutral Position Switch I00756 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 726 10 − 16 V (C18−15 ↔ C18−13) Depress brake pedal 10 − 16 V STP− ↔ GND G−W ↔ BR (C18−16 ↔ C18−13) Release brake pedal Below 1 V 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 727 Actuator control plate fully closed VR3 ↔ GND Y−L ↔ BR Constant Below 1 V (C18−25 ↔ C18−13) L− ↔ GND ↔ BR Constant Below 1 V (C18−26 ↔ C18−13) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 728 DTC is not output, or is output when is should not be. 2. Cruise Control ECU IN−28 Cruise MAIN indicator light remains ON or fall to light up. 1. Cruise MAIN Indicator Light Switch Circuit DI−332 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 729 S Harness or connector between cruise control ECU and Short in actuator motor circuit. actuator motor S Cruise control ECU WIRING DIAGRAM Cruise Control Actuator Cruise Control ECU L−R C17 MO I00488 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 730 Check for open and short in harness and connectors between cruise control ECU and actuator motor (See page IN−28). Repair or replace harness or connector. Check and replace cruise control ECU. (See page IN−28). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 731 S Cruise control ECU WIRING DIAGRAM Cruise Control ECU W−B L− Cruise Control Actuator Stop Light Switch R−G STOP G−W G−O STP− Instrument Panel Fuse Block Fusible Link Battery I00489 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 732 Switch position Continuity Switch pin free 1 − 2 (Brake pedal depressed) Switch pin pushed in 3 − 4 (Brake pedal released) I00133 Replace stop light switch. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 733 ECU and actuator magnetic clutch, actuator magnetic clutch and body ground (See page IN−28). Repair or replace harness or connector. Check and replace cruise control ECU (See page IN−28). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 734 S Harness or connector between cruise control ECU and S 13 S Position sensor detects abnormal voltage. actuator position sensor S Cruise control ECU WIRING DIAGRAM Cruise Control Actuator Cruise Control ECU Y−L Y−G I00490 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 735 Disconnect the actuator connector. CHECK: Measure resistance between actuator terminal 1 and 3 of ac- tuator connector. Resistance: 1.8 − 2.2 kΩ (25 °C) I00006 Replace cruise control actuator. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 736 Check for open and short in harness and connector between cruise control ECU and actuator position sensor (See page IN−28). Repair or replace harness or connector. Check and replace cruise control ECU (See page IN−28). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 737 Do not connect the high tension cables to the wrong bat- tery terminal. You will damage the cruise control actuator. I00054 Move the control plate by hand. Control plate does not move. Replace cruise control actuator. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 738 Check harness and connector between cruise control ECU and cruise control ac- tuator (See page IN−28). Repair or replace harness or connector. Check and replace cruise control ECU (See page IN−28). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 739 S Speed signal is not input to the cruise control ECU while bination meter, combination meter and vehicle speed sensor cruise control is set. S Vehicle speed sensor S Cruise control ECU 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 740 R−G R−G Vehicle Speed Sensor (Combination Meter) Air Intake Chamber JUNCTION CONNECTOR GAUGE B−Y Ignition Switch Instrument Panel Fuse Block B−L Battery FL MAIN Fusible Link I00491 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 741 Check harness and connector between cruise control ECU and combination me- ter, combination meter and vehicle speed sensor (See page IN−28). Repair or replace harness or connector. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 742 Brought to you by BirfMark DI−309 DIAGNOSTICS − CRUISE CONTROL SYSTEM Check vehicle speed sensor (See page BE−34). Replace vehicle speed sensor. Check and replace cruise control ECU (See page IN−28). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 743 WIRING DIAGRAM See page DI−306. INSPECTION PROCEDURE Check vehicle speed sensor (See page BE−34). Replace vehicle speed sensor. Check and replace cruise control ECU (See page IN−28). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...

  • Page 744: Cruise Control Switch

    S Cruise control ECU WIRING DIAGRAM Cruise Control Switch Cruise Control ECU MAIN Y−R CANCEL SET/COAST RESUME/ ACCEL B−G C15 20 I00492 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 745 (−) SET/COAST 2.3 − 4.6 V CANCEL 4.1 − 7.2 V AB0119 I00136 I00162 Proceed to next circuit inspection shown on problem symptoms table (See page DI−295) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 746 (See page Repair or replace harness or connector. Input signal check (See step 1). Wait and see. Check and replace cruise control ECU (See page IN−28). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 747 ON SW ON The indicator light goes off when the brake pedal is depressed. Proceed to next circuit inspection shown on problem symptoms table (See page DI−295). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 748 Check for open in harness and connectors between terminal STP− of cruise con- trol ECU and stop light switch (See page IN−28). Repair or replace harness or connector. Check and replace cruise control ECU (See page IN−28). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 749 If the idle switch is malfunctioning, problem symptoms also occur in the en- gine, so also inspect the engine. WIRING DIAGRAM Cruise Control ECU G−W G−W G−W Threottle Position Sensor I00493 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 750 Check harness and connector between ECM and throttle position sensor (See page IN−28). Repair or replace harness or connector. Check throttle position sensor circuit (See page DI−35). Replace throttle position sensor. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 751 (See page IN−28). Repair or replace harness or connector. Check and replace cruise control ECU (See page IN−28). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 752 WIRING DIAGRAM Cruise Control ECU G−O R−Y G−R R−Y 2 EC2 R−Y Ellectronically Controlled Transmission Solenoid I00494 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 753 Measure voltage between terminal OD of harness side connec- tor of ECU and body ground. Voltage: 10 − 14 V (−) AB0119 I00025 I00012 Go to step 5. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 754 Check harness and connector between terminal OD of cruise control ECU and terminal OD1 of ECM (See page IN−28). Repair or replace harness or connector. Check and replace cruise control ECU (See page IN−28). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 755 A/T Indicator Light Cruise Control ECU JUNCTION (Park/Neutral Position Switch) CONNECTOR B−O B−O Instrument Panel Fuse Block Fusible Link B−Y Ignition Switch Fusible Link FL AM1 B−L Battery I00495 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 756 D position) The indicator light goes off when shifting into except D position. Proceed to next circuit inspection shown on problem symptoms table (See page DI−295). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 757 Check harness and connector between cruise control ECU and park/neutral position switch (See page IN−28). Repair or replace harness or connector. Check and replace cruise control ECU (See page IN−28). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 758 ECU case are grounded. WIRING DIAGRAM Cruise Control ECU Instrument Panel Fuse Block ECU−IG B−Y B−W B−W Ignition Switch JUNCTION CONNECTOR Fusible Link Fusible Link Battery I00496 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 759 Measure voltage between terminals B and GND of ECU con- nector. 10 − 14 V (−) AB0119 I00014 I00027 Proceed to next circuit inspection shown on problem symptoms table (See page DI−295). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 760 Resistance: Below 1 Ω I00018 Repair or replace harness or connector. Check and repair harness and connector be- tween cruise control ECU and battery (See page IN−28). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 761 Remove the ECU−IG fuse from relay block No.2. CHECK: Check continuity of ECU−IG fuse. ECU−IG Fuse Continuity N18670 Check for short in all the harness and compo- nents connected to the ECU−IG fuse. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 762 Proceed to next circuit inspection shown on problem symptoms table (See page DI−295). Check and repair harness and connector be- tween battery and cruise control ECU (See page IN−28). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 763 (−) Main switch Voltage AB0119 I00013 I00028 10 − 14 V Below 2 V Proceed to next circuit inspection shown on problem symptoms table (See page DI−295). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 764 Check harness and connector between cruise control ECU and main switch (See page IN−28). Repair or replace harness or connector. Check and replace cruise control ECU (See page IN−28). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 765 When the cruise control main switch is turned ON, CRUISE MAIN indicator light lights up. WIRING DIAGRAM Cruise Control ECU JUNCTION Instrument Panel Fuse Block CONNECTOR GAUGE G−Y CRUISE MAIN Indicator (Combination Meter) Ignition Switch Fusible Link Battery B−L I00498 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 766 Proceed to next circuit inspection shown on problem symptoms table (See page DI−295). Check combination meter (See page BE−34). Replace combination meter. Check and replace cruise control ECU (See page IN−28). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 767 Measure voltage between terminals Tc and E of DLC1. Voltage: 10 − 14 V N06219 Proceed to next circuit inspection shown on problem symptoms table (See page DI−295). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 768 Check harness and connector between cruise control ECU and DLC1, DLC1 and body ground (See page IN−28). Repair or replace harness or connector. Check and replace cruise control ECU (See page IN−28). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 769 If the control cable is very loose, the vehicle’s loss of speed going uphill will be large. If the control cable is too tight, the idle RPM will become high. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...

  • Page 770: Emission Control System

    Injects a precisely timed, optimum amount of fuel for reduced exhaust emissions Remark: * For inspection and repair of the SFI system, refer to the SF section in this manual. 1996 LAND CRUISER (RM451U) Author : Date : Brought to you by BirfMark...
  • Page 771 Brought to you by BirfMark EC−2 EMISSION CONTROL − PARTS LAYOUT AND SCHEMATIC DRAWING PARTS LAYOUT AND SCHEMATIC DRAWING EC07I−06 LOCATION 1996 LAND CRUISER (RM451U) Author : Date : Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 772 Brought to you by BirfMark EC−3 EMISSION CONTROL − PARTS LAYOUT AND SCHEMATIC DRAWING EC07J−05 DRAWING 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 773 If operation is not as specified, replace the PCV valve. REMOVE CLEAN HOSE FROM PCV VALVE REINSTALL PCV VALVE VISUALLY INSPECT HOSE, CONNECTIONS AND GASKETS Check for cracks, leaks or damage. 1996 LAND CRUISER (RM451U) Author : Date : Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 774 Brought to you by BirfMark EC−5 EMISSION CONTROL − EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM EC0GA−01 COMPONENTS 1996 LAND CRUISER (RM451U) Author : Date : Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 775 If no problem is found with this inspection, system is normal; otherwise inspect each part. REMOVE CHARCOAL CANISTER WITH BRACKET REMOVE CHARCOAL CANISTER FROM BRACKET REMOVE CAP FROM CHARCOAL CANISTER 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 776 REINSTALL CHARCOAL CANISTER TO BRACKET Torque: 14 N·m (145 kgf·cm, 10 ft·lbf) REINSTALL CHARCOAL CANISTER WITH BRACKET Torque: 18 N·m (185 kgf·cm, 13 ft·lbf) DRAIN ENGINE COOLANT 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 777 Part No. 08833−00070, THREE BOND 1324 or equivalent Torque: 29 N·m (300 kgf·cm, 22 ft·lbf) Reconnect 2 vacuum hoses. REFILL WITH ENGINE COOLANT REMOVE INTAKE MANIFOLD STAY REMOVE VCV 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 778 REINSTALL CHECK VALVE HINT: Reinstall the check valve with the black pipe facing the VCV side. INSTALL INTAKE MANIFOLD STAY Torque: 36 N·m (360 kgf·cm, 26 ft·lbf) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 779 Brought to you by BirfMark EC−10 EMISSION CONTROL − EXHAUST GAS RECIRCULATION (EGR) SYSTEM EXHAUST GAS RECIRCULATION (EGR) SYSTEM EC0GC−01 COMPONENTS 1996 LAND CRUISER (RM451U) Author : Date : Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 780 INSPECT SEATING OF EGR VALVE Start the engine and check that the engine starts and runs at idle. CONNECT TOYOTA HAND−HELD TESTER OR OBD II SCAN TOOL (See page EM−10) INSPECT VSV OPERATION WITH COLD ENGINE The engine coolant temperature should be below 47°C (117°F).
  • Page 781 EXHAUST GAS RECIRCULATION (EGR) SYSTEM HINT: As a large amount of exhaust gas enters, the engine will misfire slightly. DISCONNECT TOYOTA HAND−HELD TESTER OR OBD II SCAN TOOL REMOVE VACUUM GAUGE Remove the vacuum gauge, and reconnect the vacuum hoses to the proper locations.
  • Page 782 RECONNECT VACUUM HOSES TO EGR VACUUM MODULATOR Connect the vacuum hose to R port. Connect the vacuum hose to Q port. Connect the vacuum hose to P port. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 783 Torque: 64 N·m (650 kgf·cm, 47 ft·lbf) Connect the engine wire to the clamp. Connect the vacuum hose to the EGR valve. REINSTALL EGR VACUUM MODULATOR Torque: 18 N·m (185 kgf·cm, 13 ft·lbf) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 784 HEAT INSULATOR INSPECTION Check heat insulator for damage Check for adequate clearance between TWC and heat insulator. FRONT TWC AND REAR TWC REPLACEMENT (See page EM−110) 1996 LAND CRUISER (RM451U) Author : Date : Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 785 IDLE AND/OR 2,500 RPM HINT: When doing the 2 mode (2,500 rpm and idle) test, follow the measurement order prescribed by the applicable local regula- tions. 1996 LAND CRUISER (RM451U) Author : Date : Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 786 S Defective ECT sensor High High (Black smoke from exhaust) S Faulty ECM S Faulty injector S Faulty throttle position sensor S Faulty MAF meter 1996 LAND CRUISER (RM451U) Author : Date : Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 787 If pressure stays low, a valve may be sticking or seating is improper, or there may be leakage past the gasket. REINSTALL SPARK PLUGS (See page IG−1) RECONNECT DISTRIBUTOR CONNECTOR 1996 LAND CRUISER (RM451U) Author : Date : Brought to you by BirfMark Version 1.00 - 12/21/2010...

  • Page 788: Valve Clearance

    1 revolution (360°) and align the marks as above. A16078 P05120 1996 LAND CRUISER (RM451U) Author : Date : Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 789 Turn the crankshaft to position the cam lobe of the camshaft on the adjusting valve upward. Position the notch of the valve lifter toward the spark plug side. 1996 LAND CRUISER (RM451U) Author : Date : Brought to you by BirfMark...
  • Page 790 Place a new adjusting shim on the valve lifter. Using SST (A), press down the valve lifter and re- move SST (B). 09248−06020, 09248−55050 (09248−05510) Recheck the valve clearance. 1996 LAND CRUISER (RM451U) Author : Date : Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 791 Connect the ground strap and engine wire with the 2 bolts. REINSTALL THROTTLE BODY (See page SF−48) REFILL RADIATOR WITH ENGINE COOLANT CHECK AND ADJUST IGNITION TIMING (See page EM−10) 1996 LAND CRUISER (RM451U) Author : Date : Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 792 Brought to you by BirfMark EM−8 ENGINE MECHANICAL − VALVE CLEARANCE V00831 1996 LAND CRUISER (RM451U) Author : Date : Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 793 Brought to you by BirfMark EM−9 ENGINE MECHANICAL − VALVE CLEARANCE V00832 1996 LAND CRUISER (RM451U) Author : Date : Brought to you by BirfMark Version 1.00 - 12/21/2010...

  • Page 794: Ignition Timing

    Remove the fuse cover on the instrument panel. Connect the TOYOTA hand−held tester or OBD II scan tool to the DLC3. Please refer to the TOYOTA hand−held tester or OBD II scan tool operator’s manual for further details. CONNECT TIMING LIGHT TO ENGINE CHECK IDLE SPEED Race the engine speed at 2,500 rpm for approx.

  • Page 795: Idle Speed

    Ignition timing set correctly. Transmission in neutral position. Air conditioning switched OFF. CONNECT TOYOTA HAND−HELD TESTER OR OBD II SCAN TOOL (See page EM−10) INSPECT IDLE SPEED Race the engine speed at 2,500 rpm for approx. 90 seconds. Check the idle speed.

  • Page 796: Timing Chain

    Brought to you by BirfMark EM−12 ENGINE MECHANICAL − TIMING CHAIN TIMING CHAIN EM1E8−01 COMPONENTS 1996 LAND CRUISER (RM451U) Author : Date : Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 797 Disconnect the No. 2 radiator hose from the water inlet. Remove the 2 nuts and radiator pipe. REMOVE WATER PUMP Remove the 4 bolts, 2 nuts, water pump and gasket. REMOVE CYLINDER HEAD (See page EM−28) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 798 REMOVE CRANKSHAFT PULLEY Using SST, remove the pulley bolt. 09213−58012, 09330−00021 Remove the crankshaft pulley. HINT: If necessary, remove the pulley with SST. 09950−50010 (09951−05010, 09952−05010, 09953−05010, 09953−05020, 09954−05020) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 799 Be careful not to damage the contact surfaces of the cylin- der block and oil pump. Remove the O−rings from the oil pump. Remove the gasket from the oil pump. REMOVE TIMING CHAIN AND CAMSHAFT TIMING GEAR 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 800 REMOVE PUMP DRIVE SHAFT GEAR If the pump drive shaft gear cannot be removed by hand, use 2 screwdrivers. NOTICE: Position shop rags as shown to prevent damage. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 801 If the wear is greater than maximum, replace the slipper and/or damper. INSPECT OIL JET Check the oil jet for damage or clogging. If necessary, replace the oil jet. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 802 Brought to you by BirfMark EM−18 ENGINE MECHANICAL − TIMING CHAIN EM1Q5−01 REPLACEMENT REPLACE CRANKSHAFT FRONT OIL SEAL (See page EM−99) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 803 Install the damper with the 2 bolts. Torque: 20 N·m (200 kgf·cm, 14 ft·lbf) Using a 10 mm hexagon wrench, install the slipper with the bolt. Torque: 69 N·m (700 kgf·cm, 51 ft·lbf) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 804 Install the timing chain on the crankshaft timing gear with the other bright link aligned with the timing mark on the crankshaft timing gear. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 805 Otherwise the material must be removed and reapplied. Immediately remove nozzle from the tube and rein- stall cap. Place 2 new O−rings in position on the timing chain cover. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 806 INSTALL NO. 2 OIL PAN (See page LU−12) INSTALL BOLTS HOLDING NO. 1 OIL PAN TO TRANS- MISSION HOUSING Install the 6 bolts. Torque: 72 N·m (730 kgf·cm, 53 ft·lbf) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 807 Install and adjust the drive belt (See page CH−2). INSTALL RADIATOR (See page CO−16) FILL ENGINE WITH OIL INSTALL ENGINE UNDER COVER START ENGINE AND CHECK FOR LEAKS 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...

  • Page 808: Cylinder Head

    Brought to you by BirfMark EM−24 ENGINE MECHANICAL − CYLINDER HEAD CYLINDER HEAD EM1E2−01 COMPONENTS 1996 LAND CRUISER (RM451U) Author : Date : Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 809 Brought to you by BirfMark EM−25 ENGINE MECHANICAL − CYLINDER HEAD 1996 LAND CRUISER (RM451U) Author : Date : Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 810 Brought to you by BirfMark EM−26 ENGINE MECHANICAL − CYLINDER HEAD 1996 LAND CRUISER (RM451U) Author : Date : Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 811 Brought to you by BirfMark EM−27 ENGINE MECHANICAL − CYLINDER HEAD 1996 LAND CRUISER (RM451U) Author : Date : Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 812 Remove the 2 bolts and disconnect the heater valve. REMOVE NO. 2 AND NO. 3 CYLINDER HEAD COVERS Remove the 4 bolts and head covers. REMOVE DISTRIBUTOR (See page IG−10) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 813 Disconnect the ECT sensor connector. Disconnect the knock sensor connector. Disconnect the crankshaft position sensor connec- tor. Remove the bolt and disconnect the engine wire from the cylinder block. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 814 Disconnect the engine wire from the cylinder head and in- take manifold. DISCONNECT NO. 2 WATER BYPASS PIPE Remove the 3 bolts, and disconnect the bypass pipe from the cylinder head. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 815 REMOVE WATER BYPASS OUTLET AND PIPE Remove the 2 bolts and water bypass outlet and pipe. Remove the 3 O−rings from the water bypass outlet and pipe. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 816 Remove the semi−circular plug. Place the matchmarks on the camshaft timing gear and timing chain. Hold the intake camshaft with a wrench, remove the bolt and distributor gear. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 817 Lightly push the camshaft towards the rear without applying excessive force. Loosen and remove the No. 1 bearing cap bolts, al- ternately loosening the left and right bolts uniformly. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 818 Lightly push the intake camshaft towards the front without applying excessive force. Loosen and remove the No. 1 bearing cap bolts, al- ternately loosening the left and right bolts uniformly. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 819 Using a screwdriver, turn the sub−gear clockwise, and re- move the service bolt (B). NOTICE: Be careful not to damage the camshaft. Using snap ring pliers, remove the snap ring. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 820 If the cylinder head is difficult to lift off, pry between the cylinder head and cylinder block with a screwdriver. NOTICE: Be careful not to damage the contact surfaces of the cylin- der head and cylinder block. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 821 Disconnect the vacuum sensing hose from the fuel pres- sure regulator. Remove the 6 bolts, 2 nuts, air intake chamber and 2 gas- kets from the intake manifold. REMOVE NO. 1 WATER BYPASS HOSE 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 822 Using SST, compress the valve spring and remove the 2 keepers. 09202−70020 (09202−00010) Remove the spring retainer, valve spring and valve. Using needle−nose pliers, remove the oil seal. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 823 Arrange the valves, valve springs, spring seats and spring re- tainers in correct order. REMOVE ECT SENDER GAUGE REMOVE ECT CUT SWITCH REMOVE ECT SENSOR REMOVE TVV 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 824 NOTICE: Be careful not to scratch the cylinder block contact sur- face. Using a valve guide bushing brush and solvent, clean all the guide bushings. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 825 If cracked, replace the cylinder head. CLEAN VALVES Using a gasket scraper, chip off any carbon from the valve head. Using a wire brush, thoroughly clean the valve. EM0580 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 826 Check the valve head margin thickness. Margin thickness: Standard 1.2 mm (0.047 in.) Minimum 1.0 mm (0.039 in.) If the margin thickness is less than minimum, replace the valve. Margin Thickness EM0181 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 827 Check that the seat contact is in the middle of the valve face with these width: P04415 Intake 1.2 − 1.6 mm (0.047 − 0.063 in.) Exhaust 1.0 − 1.4 mm (0.039 − 0.055 in.) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 828 Using vernier calipers, measure the free length of the valve spring. Free length: 43.94 − 45.06 mm (1.7299 − 1.7740 in.) If the free length is not as specified, replace the valve spring. EM0801 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 829 Inspect the camshaft bearings. Check that bearings for flaking and scoring. If the bearings are damaged, replace the bearing caps and cyl- inder head as a set. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 830 Maximum thrust clearance: 0.10 mm (0.0039 in.) If the thrust clearance is greater than maximum, replace the camshaft. If necessary, replace the bearing caps and cylinder head as a set. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 831 Using a precision straight edge and thickness gauge, measure the surface contacting the intake manifold for warpage. Maximum warpage: 0.30 mm (0.0118 in.) If warpage is greater than maximum, replace the air intake chamber. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 832 Maximum warpage: 0.30 mm (0.0118 in.) If warpage is greater than maximum, replace the manifold. INSPECT CHAIN TENSIONER Check that the plunger moves smoothly. P22604 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 833 (09951−07100) Using a sharp 7 mm reamer, ream the guide bushing to obtain the standard specified clearance (See page EM−40) between the guide bushing and valve stem. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 834 Using SST and a hammer, tap in a new tube gasket as shown in the illustration. 09950−60010 (09951−00480), 09950−70010 (09951−07150) Apply a light coat of MP grease to the gasket lip. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 835 INSTALL TVV Apply adhesive to 2 or 3 threads of the TVV. Adhesive: Part No.08833−00080, THREE BOND 1344, LOCTITE 242 or equivalent 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 836 Install the valve (1), spring seat (2), valve spring (3) and spring retainer (4). Using SST, compress the valve spring and place the 2 keepers around the valve stem. 09202−70020 (09202−00010) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 837 Install a new gasket and the water outlet with the 2 nuts. Torque: 21 N·m (210 kgf·cm, 15 ft·lbf) INSTALL GENERATOR BRACKET Install the generator bracket with the 2 bolts. Torque: 43 N·m (440 kgf·cm, 32 ft·lbf) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 838 Retighten the cylinder head bolts by 90° in the nu- merical order shown. Retighten the cylinder head bolts by an additional 90°. Check that the painted mark is now facing rearward. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 839 To avoid this, the follow- ing steps should be carried out. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 840 Set the timing mark (2 dot marks) of the camshaft drive gear at approx. 35° angle by turning the hexa- gon wrench head portion of the intake camshaft with a wrench. A16077 P22567 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 841 (14) Remove the service bolt. (15) Check that the intake and exhaust camshafts turn smoothly. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 842 Hold the intake camshaft with a wrench, install and torque the bolt. Torque: 74 N·m (750 kgf·cm, 54 ft·lbf) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 843 A16075 P08374 Valve clearance (Cold): Intake 0.15 − 0.25 mm (0.006 − 0.010 in.) Exhaust 0.25 − 0.35 mm (0.010 − 0.041 in.) INSTALL SPARK PLUGS 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 844 Apply soapy water to the O−rings. Assemble the water bypass outlet and pipe. Install the water bypass outlet and pipe with the 2 bolts. Torque: 21 N·m (210 kgf·cm, 15 ft·lbf) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 845 Connect the connector for the emission control valve set assembly. Connect the 3 injector connectors. Install the bolt holding the engine wire to the intake man- ifold. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 846 Install the dipstick guide with the 2 bolts. Torque: 20 N·m (200 kgf·cm, 14 ft·lbf) INSTALL THROTTLE BODY (See page SF−48) INSTALL GENERATOR AND DRIVE BELTS (See page CH−19) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 847 Connect the ground strap to the air intake chamber. CONNECT THROTTLE CABLE TO THROTTLE BODY CONNECT ACCELERATOR CABLE TO THROTTLE BODY CONNECT CRUISE CONTROL ACTUATOR CABLE TO THROTTLE BODY 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 848 START ENGINE AND CHECK FOR LEAKS ADJUST IGNITION TIMING (See page EM−10) PERFORM ROAD TEST Check for abnormal noise, shock, slippage, correct shift points and smooth operation. RECHECK ENGINE COOLANT LEVEL 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...

  • Page 849: Engine Unit

    Brought to you by BirfMark EM−65 ENGINE MECHANICAL − ENGINE UNIT ENGINE UNIT EM1EC−01 COMPONENTS 1996 LAND CRUISER (RM451U) Author : Date : Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 850 Brought to you by BirfMark EM−66 ENGINE MECHANICAL − ENGINE UNIT 1996 LAND CRUISER (RM451U) Author : Date : Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 851 Brought to you by BirfMark EM−67 ENGINE MECHANICAL − ENGINE UNIT 1996 LAND CRUISER (RM451U) Author : Date : Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 852 Brought to you by BirfMark EM−68 ENGINE MECHANICAL − ENGINE UNIT 1996 LAND CRUISER (RM451U) Author : Date : Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 853 REMOVE AIR CLEANER HOSE AND CAP REMOVE AIR CLEANER CASE DISCONNECT CRUISE CONTROL ACTUATOR CABLE FROM THROTTLE BODY DISCONNECT ACCELERATOR CABLE FROM THROTTLE BODY DISCONNECT HEATER HOSES 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 854 Remove the 2 nuts holding the radiator pipe to the No. 1 oil pan. Disconnect the No. 2 radiator hose from the water inlet and remove the radiator pipe. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 855 REMOVE STABILIZER BAR Remove the 2 bolts and disconnect stabilizer bar from the bracket. Remove the bolt and nut, and remove the stabilizer bar from the axle housing. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 856 Remove the transfer shift lever knob. Remove 4 screws. Lift up the console slightly in order to disconnect the con- nector. Remove the console. Remove the 3 bolts and console box. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 857 DISCONNECT GROUND STRAP FROM HEAT INSULA- PLACE JACK UNDER TRANSMISSION Be sure to put a wooden block between the jack and the trans- mission oil pan to prevent damage. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 858 Pull out the dipstick guide and dipstick from the transmis- sion. Remove the O−ring from the dipstick guide. DISCONNECT ENGINE WIRE FROM TRANSMISSION Disconnect the PNP switch connector. Disconnect the 2 connectors from the transmission. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 859 REMOVE 6 TORQUE CONVERTER CLUTCH MOUNT- ING BOLT Turn the crankshaft to gain access to each bolt. Remove the 6 bolts. REMOVE TRANSMISSION FROM ENGINE Remove the 10 bolts and transmission. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 860 Torque: 39 N·m (400 kgf·cm, 29 ft·lbf) Connect the starter connector. CONNECT ENGINE WIRE TO TRANSMISSION Connect the 2 connectors from the transmission. Connect the PNP switch connector. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 861 Torque: 19.5 N·m (195 kgf·cm, 14 ft·lbf) 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) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 862 Fully turn the control shaft lever back and return 2 notches. It is now in neutral position. Connect the transmission control rod with the nut. Torque: 13 N·m (130 kgf·cm, 9 ft·lbf) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 863 Bounce the vehicle up and down to stabilize the suspen- sion. Torque the bolt and nut holding the stabilizer bar to the axle housing. Torque: 25 N·m (260 kgf·cm, 19 ft·lbf) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 864 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) Connect the fuel return hose. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 865 CHECK IGNITION TIMING (See page EM−10) INSTALL HOOD PERFORM ROAD TEST Check for abnormal noise, shock, slippage, correct shift points and smooth operation. RECHECK ENGINE COOLANT AND ENGINE OIL LEV- 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...

  • Page 866: Cylinder Block

    Brought to you by BirfMark EM−82 ENGINE MECHANICAL − CYLINDER BLOCK CYLINDER BLOCK EM1EF−01 COMPONENTS 1996 LAND CRUISER (RM451U) Author : Date : Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 867 REMOVE OIL FILTER UNION REMOVE KNOCK SENSORS Using SST, remove the 2 knock sensors. 09816−30010 REMOVE PS PUMP Remove the 2 nuts and pump. Remove the O−ring from the pump. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 868 0.160 − 0.262 mm (0.0063 − 0.0103 in.) Maximum thrust clearance: 0.362 mm (0.0143 in.) If the thrust clearance is greater than maximum, replace the connecting rod assembly. If necessary, replace the crankshaft. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 869 If the crank pin or bearing is damaged, replace the bearings. If necessary, grind or replace the crankshaft. Lay a strip of Plastigage across the crank pin. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 870 56.994 − 57.000 mm (2.2439 − 2.2441 in.) Mark ”2” 56.988 − 56.994 mm (2.2436 − 2.2439 in.) Mark ”3” 56.982 − 56.988 mm (2.2434 − 2.2436 in.) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 871 2.565 − 2.615 mm (0.1010 − 0.1030 in.) REMOVE MAIN BEARING CAPS AND CHECK OIL CLEARANCE Uniformly loosen and remove the main bearing cap bolts in several passes, in the sequence shown. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 872 Lay a strip of Plastigage across each journal. Install the main bearing caps (See page EM−103). NOTICE: Do not turn the crankshaft. Remove the main bearing caps (See procedure (a) and (b) above). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 873 Lift out the crankshaft. Remove the upper main bearings and upper thrust wash- ers from the cylinder block. HINT: Arrange the main bearings and thrust washers in correct order. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 874 Using a piston ring expander, remove the 2 compression rings. Remove the 2 side rails and oil ring by hand. HINT: Arrange the rings in correct order only. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 875 HINT: The piston and pin are a matched set. Arrange the pistons, pins, rings, connecting rods and bearings in correct order. P03870 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 876 There are 3 sizes of the standard cylinder bore diameter, marked ”1”, ”2” and ”3” accordingly. The mark is stamped on the top of the cylinder block. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 877 Minimum outside diameter: 10.6 mm (0.417 in.) If the diameter is less than minimum, replace the bolt. Inspect the cylinder blockl oil orifice for clogging. If necessary, replace the orifice. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 878 Inspect the piston oil clearance. HINT: There are 3 sizes of the standard piston diameter, marked ”1”, ”2” and ”3”. The mark is stamped on the piston top. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 879 No. 1 0.040 − 0.080 (0.0016 − 0.0031 in.) No. 2 0.030 − 0.070 (0.0012 − 0.0028 in.) If the clearance is greater than maximum, replace the piston. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 880 Check for out−of−alignment. Maximum out−of−alignment: 0.05 mm (0.0020 in.) per 100 mm (3.94 in.) If out−of−alignment is greater than maximum, replace the con- necting rod assembly. P03829 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 881 Standard outside diameter: 8.40 − 8.60 mm (0.3307 − 0.3386 in.) Minimum outside diameter: 8.00 mm (0.3150 in.) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 882 AND/OR CRANK PINS Grind and hone the main journals and/or crank pins to the fin- ished undersized diameter. Install new main journal and/or crankshaft pin undersized bearings. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 883 Check the piston pin fit at normal room temperature. Coat the piston pin with engine oil, and push it into the connect- ing rod with your thumb. P03867 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 884 09316−60011 (09316−00011, 09316−00051) Apply MP grease to the oil seal lip. NOTICE: Do not let foreign matter get onto the lip of the oil seal. P08469 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 885 Using a knife, cut off the oil seal lip. Using a screwdriver, pry out the oil seal. NOTICE: Be careful not to damage the crankshaft. Tape the screw- driver tip. Cut Position P08643 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 886 Do not let foreign matter get onto the lip of the oil seal. Check that the lip of the oil seal is not bent inward. WRONG P23172 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 887 Install the oil ring expander and 2 side rails by hand. Using a piston ring expander, install the 2 compression rings with the code mark facing upward. Code mark: No. 1 No. 2 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 888 Align the pin of the oil nozzle with the pin hole of the cylin- der block. Install the oil nozzle with the check valve. Install the 6 oil nozzles and check valves. Torque: 25 N·m (250 kgf·cm, 18 ft·lbf) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 889 Place the main bearing caps and lower thrust washers on the cylinder block. Install the 2 thrust washers on the No.4 bearing cap with the grooves facing outward. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 890 Check that the crankshaft thrust clearance (See page EM−83). INSTALL PISTON AND CONNECTING ROD AS- SEMBLIES Cover the connecting rod bolts with a short piece of hose to protect the crankshaft from damage. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 891 Mark the front of the connecting rod cap nut and bolt with paint. Retighten the connecting rod cap nuts 90° as shown. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 892 INSTALL OIL COOLER COVER AND OIL COOLER Install a new gasket, the oil cooler cover and oil cooler with the 10 bolts and 2 nuts. Torque: 21 N·m (210 kgf·cm, 15 ft·lbf) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 893 Install the front spacer, drive plate and rear plate on the crankshaft. Install and uniformly tighten the 10 drive plate bolts, in several passes, in the sequence shown. Torque: 100 N·m (1,000 kgf·cm, 74 ft·lbf) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...

  • Page 894: Exhaust System

    Brought to you by BirfMark EM−110 ENGINE MECHANICAL − EXHAUST SYSTEM EXHAUST SYSTEM EM0EE−10 COMPONENTS 1996 LAND CRUISER (RM451U) Author : Date : Brought to you by BirfMark Version 1.00 - 12/21/2010...

  • Page 895: Ignition System

    Check wiring between ECM, ignition coil and CHECK IGT SIGNAL FROM ECM igniter, and then try another ECM. (See page DI−93) TRY ANOTHER IGNITER 1996 LAND CRUISER (RM451U) Author : Date : Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 896 DISCONNECT HIGH−TENSION CORDS FROM DIS- TRIBUTOR CAP AND IGNITION COIL Using a screwdriver, lift up the lock claw and disconnect the holder from the distributor cap (ignition coil). 1996 LAND CRUISER (RM451U) Author : Date : Brought to you by BirfMark...
  • Page 897 Connect the high−tension cords to the distributor cap as shown in the illustration. Align the spline of the distributor (ignition coil) with the spline of the holder, and push in the cord. 1996 LAND CRUISER (RM451U) Author : Date : Brought to you by BirfMark...
  • Page 898 Check that the lock claw of the holder is engaged by lightly pulling the holder. RECONNECT HIGH−TENSION CORDS TO SPARK PLUGS Secure the high−tension cords with the cord clamps as shown in the illustration. 1996 LAND CRUISER (RM451U) Author : Date : Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 899 Check the spark plug for electrode wear, threads damage and insulator damage. If abnormal, replace the plugs. Recommended spark plugs: ND: K16R−U NGK: BKR5EYA P03783 1996 LAND CRUISER (RM451U) Author : Date : Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 900 Hot: 11.4 − 18.1 kΩ If the resistance is not as specified, replace the ignition coil. RECONNECT HIGH−TENSION CORD RECONNECT IGNITION COIL CONNECTOR 1996 LAND CRUISER (RM451U) Author : Date : Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 901 ”Cold” and ”Hot” in the following sentences express the temperature of the sensor itself. ”Cold” is from −10°C (14°F) to 50°C (122°F) and ”Hot” is from 50°C (122°F) to 100°C (212°F). 1996 LAND CRUISER (RM451U) Author : Date : Brought to you by BirfMark...
  • Page 902 Hot: 2,065 − 3,225 Ω If the resistance is not as specified, replace the crankshaft posi- tion sensor. P22961 RECONNECT CRANKSHAFT POSITION SENSOR BRACKET AND CONNECTOR 1996 LAND CRUISER (RM451U) Author : Date : Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 903 Brought to you by BirfMark IG−9 IGNITION − DISTRIBUTOR DISTRIBUTOR IG0IC−01 COMPONENTS 1996 LAND CRUISER (RM451U) Author : Date : Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 904 If not, turn the crankshaft pulley one complete revolution. REMOVE DISTRIBUTOR Remove the hold−down bolt and pull out the distributor. Remove the O−ring from the distributor housing. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 905 Insert the distributor, aligning the center of the flange with that of the bolt hole on the cylinder head. Lightly tighten the hold−down bolt. INSTALL DISTRIBUTOR CAP CONNECT DISTRIBUTOR CONNECTOR CHECK IGNITION TIMING (See page EM−10) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...

  • Page 906: Crankshaft Position Sensor

    Brought to you by BirfMark IG−12 IGNITION − CRANKSHAFT POSITION SENSOR CRANKSHAFT POSITION SENSOR IG0JW−01 COMPONENTS 1996 LAND CRUISER (RM451U) Author : Date : Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 907 REMOVE CRANKSHAFT POSITION SENSOR Remove the bolt, 2 nuts and crankshaft position sensor. Torque: Bolt A: 20 N·m (200 kgf·cm, 14 ft·lbf) Nut B: 9 N·m (90 kgf·cm, 78 in.·lbf) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 908 Brought to you by BirfMark IG−14 IGNITION − CRANKSHAFT POSITION SENSOR IG0JY−01 INSTALLATION Installation is in the reverse order of removal (See page IG−13). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 909 Adhesive: Part No. 08833−00080, THREE BOND 1344, LOCTITE 242 or equivalent Reinstall the oil pressure switch. START ENGINE AND CHECK FOR LEAKS P08343 1996 LAND CRUISER (RM451U) Author : Date : Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 910 6.9 liters (7.3 US qts, 6.1 lmp. qts) Dry fill 8.0 liters (8.5 US qts, 7.0 lmp. qts) Reinstall the oil filler cap. START ENGINE AND CHECK FOR LEAKS RECHECK ENGINE OIL LEVEL 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...

  • Page 911: Oil Pump

    Brought to you by BirfMark LU−3 LUBRICATION − OIL PUMP OIL PUMP LU0KF−04 COMPONENTS 1996 LAND CRUISER (RM451U) Author : Date : Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 912 Brought to you by BirfMark LU−4 LUBRICATION − OIL PUMP 1996 LAND CRUISER (RM451U) Author : Date : Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 913 REMOVE WATER PUMP Remove the 4 bolts, 2 nuts, water pump and gasket. REMOVE CYLINDER HEAD (See page EM−28) DISCONNECT OIL COOLER PIPE BRACKET FROM NO.1 OIL PAN 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 914 Be careful not to damage the No.2 oil pan contact surface of the No.1 oil pan.Be careful not to damage the oil pan flange. REMOVE NO.1 OIL PAN Remove the 21 mounting bolts and 2 nuts. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 915 REMOVE DRIVE BELT IDLER PULLEY Remove the bolt and idler pulley. REMOVE OIL PUMP (TIMING CHAIN COVER) (See page EM−13) REMOVE TIMING CHAIN AND CAMSHAFT TIMING GEAR 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 916 Remove the plug, gasket, spring and relief valve. Torque: 49 N·m (500 kgf·cm, 36 ft·lbf) HINT: At the time of installation, install a new gasket to the plug. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 917 0.030 − 0.160 mm (0.0012 − 0.0063 in.) Maximum tip clearance: 0.25 mm (0.0098 in.) If the tip clearance is greater than maximum, replace the rotors as a set. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 918 Brought to you by BirfMark LU−10 LUBRICATION − OIL PUMP LU08T−03 REPLACEMENT REPLACE CRANKSHAFT FRONT OIL SEAL (See page EM−99) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 919 Brought to you by BirfMark LU−11 LUBRICATION − OIL PUMP LU0KJ−01 REASSEMBLY Reassembly is in the reverse order of disassembly (See page LU−8). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 920 Parts must be assembled within 5 minutes of ap- plication. Otherwise the material must be removed and reapplied. Immediately remove nozzle from the tube and rein- stall cap. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 921 Install the No.2 oil pan with the 17 bolts and 2 nuts. Torque: 7.8 N·m (80 kgf·cm, 69 in.·lbf) Torque: 8.8 N·m (90 kgf·cm, 78 in.·lbf) INSTALL BOLTS HOLDING NO.1 OIL PAN TO TRANS- MISSION HOUSING 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 922 Install and adjust the drive belt (See page CH−2). INSTALL RADIATOR (See page CO−16) INSTALL ENGINE UNDER COVER FILL WITH ENGINE OIL START ENGINE AND CHECK FOR LEAKS 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...

  • Page 923: Oil Cooler

    Brought to you by BirfMark LU−15 LUBRICATION − OIL COOLER OIL COOLER LU08W−03 COMPONENTS 1996 LAND CRUISER (RM451U) Author : Date : Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 924 Remove the 4 nuts, front exhaust pipe and 2 gaskets. REMOVE NO.1 EXHAUST MANIFOLD Remove the 3 bolts and No.1 heat insulator. Remove the 6 nuts, exhaust manifold and gasket. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 925 SEPARATE OIL COOLER AND OIL COOLER COVER Remove the 4 nuts, oil cooler and 2 gaskets from the oil cooler cover. REMOVE RELIEF VALVE Remove the plug, gasket, spring and relief valve. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 926 If it doesn’t, replace the relief valve. If necessary, replace the oil cooler cover. INSPECT OIL COOLER Check the oil cooler for damage or clogging. If necessary, replace the oil cooler. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 927 Torque: 46 N·m (470 kgf·cm, 34 ft·lbf) INSTALL AIR CLEANER CAP AND HOSE FILL RADIATOR WITH ENGINE COOLANT START ENGINE AND CHECK FOR LEAKS CHECK ENGINE OIL 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 928 Brought to you by BirfMark LU−20 LUBRICATION − OIL NOZZLE OIL NOZZLE LU0KL−01 COMPONENTS 1996 LAND CRUISER (RM451U) Author : Date : Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 929 Torque: 25 N·m (250 kgf·cm, 18 ft·lbf) HINT: At the time of installation, align the pin of the nozzle with the pin hole of the cylinder block. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 930 Push the valve with a wooden stick to check if it is stuck. If stuck, replace the check valve. INSPECT OIL NOZZLES Check the oil nozzles for damage or clogging. If necessary, replace the oil nozzle. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 931 Brought to you by BirfMark LU−23 LUBRICATION − OIL NOZZLE LU0KO−01 INSTALLATION Installation is in the reverse order of removal (See page LU−21). 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...

  • Page 932: Outside Vehicle

    Check that all doors and the tailgate operate smoothly, and that all larches lock securely. Check that the engine hood secondary latch secures the hood from opening when the primary latch is released. 1996 LAND CRUISER (RM451U) Author : Date : Brought to you by BirfMark Version 1.00 - 12/21/2010...

  • Page 933: Inside Vehicle

    SEAT BELTS Check that the seat belt system such as buckles, retractors and anchors operate properly and smooth- Check that the belt webbing is not cut, frayed, worn or damaged. 1996 LAND CRUISER (RM451U) Author : Date : Brought to you by BirfMark...
  • Page 934 Check the lock release button of the selector level for proper and smooth operation. On a safe incline, check that the vehicle is held securely with the selector lever in the P position and all brakes released. 1996 LAND CRUISER (RM451U) Author : Date : Brought to you by BirfMark Version 1.00 - 12/21/2010...

  • Page 935: Under Hood

    Visually inspect for cracks, holes or loose supports. If any change in the sound of the exhaust or smell of the exhaust fumes is noticed, have the cause located and corrected. 1996 LAND CRUISER (RM451U) Author : Date : Brought to you by BirfMark...
  • Page 936 INSPECT EXHAUST PIPES AND MOUNTINGS Visually inspect the pipes, hangers and connections for severe corrosion, leaks or damage. ADJUST VALVE CLEARANCE (See page EM−4) 1996 LAND CRUISER (RM451U) Author : Date : Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 937 INSPECT FRONT BRAKE PADS AND DISCS (See page BR−27) INSPECT REAR BRAKE PADS AND DISCS (See page BR−36) INSPECT PARKING BRAKE LININGS AND DRUMS (See page BR−42) 1996 LAND CRUISER (RM451U) Author : Date : Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 938 Oil drade: Hypoid gear oil API GL−5 Viscosity: Above −18°C (0°F) SAE 90 Below −18°C (0°F) SAE 80W−90 or 80W P22573 REPLACE AUTOMATIC TRANSMISSION FLUID (See page DI−3) 1996 LAND CRUISER (RM451U) Author : Date : Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 939 Grease grade: Lithium base chassis grease (NLGI No. 2) Lubricating Positions: 1. Spider 2. Slide Yoke MA0621 B13835 1996 LAND CRUISER (RM451U) Author : Date : Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 940 Be sure to deliver a clean car. Especially check the steering wheel, shift lever knob, all switch knobs, door handles and seats. 1996 LAND CRUISER (RM451U) Author : Date : Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 941 Brought to you by BirfMark PP−1 PREPARATION − MAINTENANCE MAINTENANCE PP2ZZ−01 EQUIPMENT Mirror Brake hose Torque wrench 1996 LAND CRUISER (RM451U) Author : Date : Brought to you by BirfMark Version 1.00 - 12/21/2010...

  • Page 942: Engine Mechanical

    Valve stem oil seal 09248−06020 Valve Lifter Stopper 09248−55050 Valve Clearance Adjust Tool Set (09248−05510) Valve Lifter Press 09316−60011 Transmission & Transfer Bearing Replacer 1996 LAND CRUISER (RM451U) Author : Date : Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 943 Crankshaft timing gear (09951−04010) Hanger 150 (09952−04010) Slide Arm (09953−04020) Center Bolt 150 (09954−04010) Arm 25 (09955−04061) Claw No.6 09950−50012 Puller C Set Crankshaft pulley 1996 LAND CRUISER (RM451U) Author : Date : Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 944 Connecting rod bushing (09951−00350) Replacer 35 Crankshaft timing gear (09951−00480) Replacer 48 Spark plug tube gasket 09950−70010 Handle Set (09951−07100) Handle 100 (09951−07150) Handle 150 1996 LAND CRUISER (RM451U) Author : Date : Brought to you by BirfMark Version 1.00 - 12/21/2010...

  • Page 945: Recommended Tools

    ENGINE MECHANICAL PP301-01 RECOMMENDED TOOLS 09082-00040 TOYOTA Electrical Tester. 09200-00010 Engine Adjust Kit . Hose Plug Set . Plug for the vacuum hose, fuel hose 09258-00030 etc. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 946 Piston ring compressor Piston ring expander Plastigage Precision straight edge Soft brush Spring tester Valve spring Steel square Valve spring Thermometer Torque wrench Valve seat cutter Vernier calipers 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 947 Semi−circular plug Oil pan Rear oil seal retainer 08833−00070 Adhesive 1324, Plug tube THREE BOND 1324 or equivalent 08833−00080 Adhesive 1344 THREE BOND 1344 LOCTITE 242 or equivalent 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...

  • Page 948: Emission Control

    Brought to you by BirfMark PP−8 PREPARATION − EMISSION CONTROL EMISSION CONTROL PP305−02 RECOMMENDED TOOLS 09082−00040 TOYOTA Electrical Tester. 1996 LAND CRUISER (RM451U) Author : Date : Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 949 Brought to you by BirfMark PP−9 PREPARATION − EMISSION CONTROL PP306−01 EQUIPMENT Heater OBD II scan tool Engine speed Thermometer Torque wrench Vacuum gauge 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 950 Brought to you by BirfMark PP−10 PREPARATION − EMISSION CONTROL PP307−01 SSM (Special Service Materials) 08833−00070 Adhesive 1324, THREE BOND 1324 or equivalent 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 951 Power Steering Hose Nut Fuel line flare nut 14 x 17 mm Wrench Set 09816−30010 Oil Pressure Switch Socket Knock sensor 09842−30070 Wiring ”F” EFI Inspection 1996 LAND CRUISER (RM451U) Author : Date : Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 952 PP−12 PREPARATION − PP309−01 RECOMMENDED TOOLS 09082−00040 TOYOTA Electrical Tester. 09200−00010 Engine Adjust Kit . 09258−00030 Hose Plug Set . Plug for vacuum hose, fuel hose, etc. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 953 PP−13 PREPARATION − PP30A−01 EQUIPMENT Carburetor cleaner Throttle body Graduated cylinder Injector OBD II scan tool Engine speed Soft brush Throttle body Sound scope Injector Torque wrench 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 954 Brought to you by BirfMark PP−14 PREPARATION − COOLING COOLING PP30B−01 EQUIPMENT Heater Thermostat Radiator cap tester Thermometer Thermostat Torque wrench 1996 LAND CRUISER (RM451U) Author : Date : Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 955 Ethylene−glycol base w/ Front heater 12.5 liters (13.2 US qts, 11.1 lmp. qts) w/ Front heater and rear heaters 13.4 liters (14.2 US qts, 11.8 lmp. qts) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 956 Brought to you by BirfMark PP−16 PREPARATION − LUBRICATION LUBRICATION PP30D−04 SST (Special Service Tools) 09032−00100 Oil Pan Seal Cutter 09228−44011 Oil Filter Wrench 1996 LAND CRUISER (RM451U) Author : Date : Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 957 Brought to you by BirfMark PP−17 PREPARATION − LUBRICATION PP30E−01 RECOMMENDED TOOLS 09200−00010 Engine Adjust Kit . 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 958 Brought to you by BirfMark PP−18 PREPARATION − LUBRICATION PP30F−01 EQUIPMENT Oil pressure gauge Precision straight edge Oil pump Torque wrench 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 959 7.4 liters (7.8 US qts, 6.5 Imp. qts) recommended viscosity oil, with SAE 5W−30 be- w/o Oil filter change 6.9 liters (7.3 US qts, 6.1 Imp qts) ing preferred engine oil 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 960 08826−00080 Seal Packing Black or equivalent Oil pump (FIPG) Oil pan (Timing chain cover) 08833−00080 Adhesive 1344 Oil pressure switch THREE BOND 1344 LOCTITE 242 or equivalent 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 961 Brought to you by BirfMark PP−21 PREPARATION − IGNITION IGNITION PP30I−01 RECOMMENDED TOOLS 09082−00040 TOYOTA Electrical Tester. 09200−00010 Engine Adjust Kit . 1996 LAND CRUISER (RM451U) Author : Date : Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 962 Brought to you by BirfMark PP−22 PREPARATION − IGNITION PP30J−01 EQUIPMENT Spark plug cleaner Torque wrench 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 963 Injection Pump Spline Shaft Armature bearing Puller 09810−38140 Starter Magnet Switch Nut Wrench Terminal nut 09820−00030 Alternator Rear Bearing Replacer Armature rear bearing 1996 LAND CRUISER (RM451U) Author : Date : Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 964 Brought to you by BirfMark PP−24 PREPARATION − STARTING PP30L−01 RECOMMENDED TOOLS 09082−00040 TOYOTA Electrical Tester. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 965 EQUIPMENT Dial indicator Commutator Magnetic finger Steel ball Press Magnetic switch terminal kit Pull scale Brush spring Sandpaper Commutator Torque wrench V−block Commutator Vernier calipers Commutator, Brush 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 966 Alternator Pulley Set Nut Wrench 09950−60010 Replacer Set (09951−00260) Replacer 26 Rotor front bearing (09951−00500) Replacer 50 Rotor front bearing (09952−06010) Adapter Rotor front bearing 1996 LAND CRUISER (RM451U) Author : Date : Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 967 Brought to you by BirfMark PP−27 PREPARATION − CHARGING PP30O−01 RECOMMENDED TOOLS 09082−00040 TOYOTA Electrical Tester. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 968 Brought to you by BirfMark PP−28 PREPARATION − CHARGING PP30P−01 EQUIPMENT Belt tension gauge Torque wrench Vernier calipers Rotor (Slip ring), Brush 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 969 One−way Clutch Test Tool (09351−32020) Stator Stopper 09921−00010 Spring Tension Tool Speedometer driven gear oil seal 09992−00095 Automatic Transmission Oil Pressure Gauge Set 1996 LAND CRUISER (RM451U) Author : Date : Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 970 Brought to you by BirfMark PP−30 PREPARATION − AUTOMATIC TRANSMISSION PP3KS−01 RECOMMENDED TOOLS 09031−00030 Pin Punch . 09082−00040 TOYOTA Electrical Tester. 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 971 PP2XS−01 EQUIPMENT Dial indicator with magnetic base Check drive plate runout OBD II scan tool Straight edge Torque converter clutch Torque wrench Vernier Calipers Torque converter clutch 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 972 Classification Automatic transmission fluid ATF DEXRON®II Dry fill 11.0 liters (11.6 US qts, 9.7 lmp. qts) Drain and refill 1.9 liters (2.0 US qts, 1.7 lmp. qts) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 973 SSM (Special Service Materials) 08826−00090 Seal Packing 1281, Oil pan THREE BOND 1281 or equivalent (FIPG) 08833−00080 Adhesive 1344 Extension housing THREE BOND 1344 LOCTITE 242 or equivalent 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 974 Rear extension housing Front extension housing (09316−00061) Replacer ”E” (09316−00071) Replacer ”F” Idler gear Front extension housing 09325−12010 Transmission Oil Plug Rear extension housing 1996 LAND CRUISER (RM451U) Author : Date : Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 975 Center differential (09951−00400) Replacer 40 Center differential 09950−70010 Handle Set Component parts removal and instal- lation Front extension housing Center differential (09951−07150) Handle 150 1996 LAND CRUISER (RM451U) Author : Date : Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 976 Pin Punch . 09040−00010 Hexagon Wrench Set . 09042−00010 Torx Socket T30 . 09042−00020 Torx Socket T40 . 09082−00040 TOYOTA Electrical Tester. 09905−00012 Snap Ring No.1 Expander . 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 977 Brought to you by BirfMark PP−37 PREPARATION − TRANSFER PP2XW−01 EQUIPMENT Dial indicator Feeler gauge Magnetic finger Straight edge Torque wrench Vernier calipers 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 978 Brought to you by BirfMark PP−38 PREPARATION − TRANSFER PP2XX−01 LUBRICANT Item Capacity Classification Transfer oil 1.7 liters (1.8 US qts, 1.5 lmp. qts) API GL−4 or GL−5 SAE 75W−90 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 979 Adhesive 1324, Dynamic damper set bolt THREE BOND 1324 or equivalent 08833−00080 Adhesive 1344 Straight screw plug THREE BOND 1344 Case cover set bolt LOCTITE 242 or equivalent 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...

  • Page 980: Propeller Shaft

    Brought to you by BirfMark PP−40 PREPARATION − PROPELLER SHAFT PROPELLER SHAFT PP2Y8−01 SST (Special Service Tools) 09332−25010 Universal Joint Bearing Remover Spider bearing & Replacer 1996 LAND CRUISER (RM451U) Author : Date : Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 981 Brought to you by BirfMark PP−41 PREPARATION − PROPELLER SHAFT PP2Y7−01 EQUIPMENT Dial indicator Torque wrench 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 982 Front differential Replacer Rear differential (09316−00011) Replacer Pipe (09316−00021) Replacer ”A” (09316−00051) Replacer ”D” 09330−00021 Companion Flange Holding Tool Front differential Rear differential 1996 LAND CRUISER (RM451U) Author : Date : Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 983 09605−60010 Steering Knuckle Bearing Cup Front axle Replacer− 09606−60020 Steering Knuckle Bearing Remover Front axle 09607−60020 Front Wheel Adjusting Nut Wrench Front axle 1996 LAND CRUISER (RM451U) Author : Date : Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 984 Replacer (09710−02071) Bushing Remover & Replacer 09710−30050 Suspension Arm Bushing Replacer Front suspension 09726−40010 Lower Control Shaft Bearing Front differential Replacer Rear differential 1996 LAND CRUISER (RM451U) Author : Date : Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 985 Adapter 18 09950−40011 Puller B Set Front differential Rear differential (09951−04010) Hanger 150 (09952−04010) Slide Arm (09953−04020) Center Bolt 150 (09954−04010) Arm 25 1996 LAND CRUISER (RM451U) Author : Date : Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 986 Replacer 54 09950−60020 Replacer Set No.2 Front axle Rear axle Rear differential (09951−00710) Replacer 71 (09951−00720) Replacer 72 (09951−00810) Replacer 81 (09951−00890) Replacer 89 1996 LAND CRUISER (RM451U) Author : Date : Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 987 SUSPENSION AND AXLE (09951−00910) Replacer 91 09950−70010 Handle Set Front axle Front suspension Rear axle Rear differential Rear suspension (09951−07100) Handle 100 (09951−07150) Handle 150 1996 LAND CRUISER (RM451U) Author : Date : Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 988 09082−00050 TOYOTA Electrical Tester Set. Differential locking system 09905−00012 Snap Ring No.1 Expander . Front axle Front differential 09905−00013 Snap Ring Pliers . Front axle Front differential 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 989 Brought to you by BirfMark PP−49 PREPARATION − SUSPENSION AND AXLE PP2YD−01 EQUIPMENT Dial indicator or dial indicator with magnetic base Feeler gauge Micrometer Spring tension gauge Torque wrench 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 990 Dfferential lock 2.65 liters (2.8 US qts, 2.3 lmp. qts) Below −18°C (0°F) SAE 80W−90 or 80W Rear 3.25 liters (3.4 US qts, 2.9 lmp. qts) 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 991 THREE BOND 1281 or equivalent Rear differential (FIPG) Differential locking system 08833−00080 Adhesive 1344 Front differential THREE BOND 1344 Rear differential LOCTITE 242 or equivalent Differential locking system 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 992 Wrench 09843−18020 Diagnosis Check Wire 09990−00150 ABS Actuator Checker and Sub−harness 09990−00200 ABS Actuator Checker Sub−harness ”C” 09990−00210 ABS Actuator Checker Sub−harness ”E” 1996 LAND CRUISER (RM451U) Author : Date : Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 993 Brought to you by BirfMark PP−53 PREPARATION − BRAKE PP2YH−01 RECOMMENDED TOOLS 09082−00040 TOYOTA Electrical Tester. 09905−00013 Snap Ring Pliers . 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 994 Brought to you by BirfMark PP−54 PREPARATION − BRAKE PP2YI−01 EQUIPMENT Dial indicator Brake disc Micrometer Brake disc Torque wrench Vernier calipers Brake disc 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 995 Brought to you by BirfMark PP−55 PREPARATION − BRAKE PP2YJ−01 LUBRICANT Item Capacity Classification Brake fluid − SAE J1703 or FMVSS No. 116 DOT 3 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 996 Oil Seal Remover PS vane pump 09631−22020 Power Steering Hose Nut PS gear 14 x 17 mm Wrench Set 09640−10010 Power Steering Pressure Gauge 1996 LAND CRUISER (RM451U) Author : Date : Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 997 09950−50010 Puller C Set (09951−05010) Hanger 150 Tilt steering column (09952−05010) Slide Arm Tilt steering column (09953−05020) Center Bolt 150 Tilt steering column 1996 LAND CRUISER (RM451U) Author : Date : Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 998 Replacer Set (09951−00360) Replacer 36 PS gear (09951−00410) Replacer 41 PS gear (09952−06010) Adapter PS gear 09950−70010 Handle Set (09951−07200) Handle 200 PS gear 1996 LAND CRUISER (RM451U) Author : Date : Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 999 09042−00010 Torx Socket T30 . Tilt steering column 09904−00010 Expander Set . (09904−00050) No. 4 Claw 09905−00012 Snap Ring No.1 Expander . 09905−00013 Snap Ring Pliers . 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...
  • Page 1000 STEERING PP2YM−01 EQUIPMENT Caliper gauge PS vane pump Calipers PS vane pump Dial indicator PS gear Feeler gauge PS vane pump Micrometer PS vane pump Torque wrench 1996 LAND CRUISER (RM451U) Brought to you by BirfMark Version 1.00 - 12/21/2010...

Table of Contents