Engine Controls - Remove/install/overhaul Toyota Land Cruiser 80

INTRODUCTION

Removal, overhaul and installation procedures are covered in this article. If component removal and installation is primarily an unbolt and bolt-on procedure, only a torque specification may be furnished.

DISTRIBUTOR

Note. For timing specifications and procedures, see ADJUSTMENTS article in the ENGINE PERFORMANCE Section.

Removal

Disconnect negative battery cable. Remove air cleaner hose. Disconnect distributor wiring connector. Disconnect ventilation hoses. Disconnect spark plug wires. Remove hold-down bolt. Remove distributor. Remove "O" ring from distributor shaft and discard.

Scheme 1

1. Remove No. 1 cylinder spark plug. Place finger over spark plug hole. Turn crankshaft clockwise until pressure is felt. This indicates No. 1 cylinder is at TDC of compression stroke. Install spark plug. Turn oil pump shaft slot. (Scheme 1)
2. Install new "O" ring into distributor housing. Coat "O" ring with oil. Install distributor with mounting flange aligned with bolt hole on cylinder head and drilled mark on drive gear facing upward. (Scheme 2)
3. Connect distributor wiring connector. Install spark plug wires. Install distributor cap. Connect negative battery cable. Set ignition timing.Tighten distributor hold-down bolt. See TORQUE SPECIFICATIONS at end of article.

Scheme 2

FUEL SYSTEM PRESSURE RELEASE

Disconnect negative battery terminal. Place container under fitting to be loosened. Use a rag to cover fuel line/component. Slowly loosen fitting, allowing pressurized fuel to spill into container. After fuel system pressure is released, disconnect and plug fitting.

Removal & Installation

1. Disconnect negative battery cable. Remove service hole cover, located in luggage compartment area. Release fuel pressure. See FUEL SYSTEM PRESSURE RELEASE. Disconnect and plug fuel lines at fuel pump. Remove screws securing fuel pump and bracket assembly to fuel tank. Remove fuel pump and bracket assembly.
2. Pull lower end of fuel pump (with filter) from bracket. Remove 2 nuts securing fuel pump wires to fuel pump. Disconnect wires. Disconnect fuel hose from pump. Remove fuel pump. To install, reverse removal procedure.

FUEL INJECTORS & FUEL RAILS

Note. Always install new grommets and "O" rings when removing or replacing fuel injectors. Ensure injectors rotate smoothly in injector ports and fuel rail. If injectors DO NOT rotate smoothly, check "O" rings for proper installation.

1. Disconnect negative battery cable. Disconnect accelerator and throttle cables. Disconnect emission control hoses. Disconnect all hoses and electrical connectors from intake manifold area as required.
2. Loosen 2 union nuts and remove EGR pipe. Release fuel pressure. See FUEL SYSTEM PRESSURE RELEASE. Remove cold start injector pipe. Disconnect coolant by-pass hoses. Remove 2 intake manifold brackets. Remove 7 bolts, 2 nuts and air intake chamber. Remove intake manifold temperature sensor and bracket.
3. Disconnect engine wiring harness on intake manifold. Disconnect fuel and vacuum hoses. Remove pulsation damper. Remove No. 2 fuel pipe with engine removal hook. Remove fuel pressure regulator. Remove No. 1 fuel pipe.
4. Remove 3 nuts, plate washers, spacers and fuel rail with 6 injectors. Remove 6 insulators, 6 spacers and 3 collars from intake manifold. Remove injectors from fuel rail.

Installation

1. Install new grommets and "O" rings on injectors. Install 6 injectors on fuel rails. Install 6 insulators, 6 spacers and 3 collars on intake manifold.
2. Install 6 injectors with fuel rail into intake manifold. Ensure injectors rotate smoothly. If injectors do not rotate smoothly, check "O" rings for proper installation. Position injector connectors upward. Install 3 fuel rail spacers, washers and nuts.
3. To complete installation, reverse removal procedure. Tighten all nuts and bolts. See TORQUE SPECIFICATIONS at end of article.

Disconnect sensor electrical connector. Remove 2 mounting nuts or bolts. Remove sensor. Some sub-oxygen sensors screw into exhaust manifold or header pipe.

Note. When removing sensor, protect its permanent pigtail from damage. Ensure sensor is free of contaminants. Avoid using cleaning solvents of any type.

Install sensor. Install nuts or bolts. Connect electrical connector. Oxygen sensor torque specification is not available from manufacturer.

1. Disconnect negative battery cable. Drain coolant. Disconnect accelerator and throttle cables from throttle linkage. Disconnect air cleaner hose. Unplug throttle position sensor. Disconnect coolant by-pass hoses(s).
2. Label and disconnect emission control vacuum hoses. Remove throttle body. To install, reverse removal procedure. Tighten all nuts and bolts. See TORQUE SPECIFICATIONS at end of article.

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS