Engine Mechanical PDF

EM-1
ENGINE MECHANICAL CO/HC
CO/HC
EM0KQ-07
INSPECTION
HINT: This check is used only to determine whether or not the idle CO/ HC complies with regulations. 1. INITIAL CONDITIONS (a) The engine is at normal operating temperature. (b) Air cleaner is installed. (c) All pipes and hoses of the air induction system are connected. (d) All accessories are switched OFF. (e) All vacuum lines are properly connected. HINT: All vacuum hoses should be properly connected. (f) SFI system wiring connectors are fully plugged. (g) Ignition timing is set correctly. (h) Transmission is in neutral range. (i) Tachometer and CO/HC meter are calibrated by hand. 2. START ENGINE 3. RACE ENGINE AT 2,500 RPM FOR APPROX. 180 SECONDS
CO/HC Meter
4. 5.
INSERT CO/HC METER TESTING PROBE AT LEAST 40 cm (1.3 ft) INTO TAILPIPE DURING IDLING IMMEDIATELY CHECK CO/HC CONCENTRATION AT IDLE AND/OR 2,500 RPM
HINT: When performing the 2 mode (2,500 rpm and idle) test, follow the measurement order prescribed by the applicable local regulations.
A05510
2004 LAND CRUISER (RM1071U)
Author :
Date :
1574
EM-2
ENGINE MECHANICAL CO/HC
6. TROUBLESHOOTING HINT: If the CO/HC concentration does not comply with the regulations, perform troubleshooting in the order given below. See the table below for possible causes, and then inspect and correct the applicable causes if necessary.
CO Normal HC High Problems Rough idle Causes 1. Faulty ignitions: L Incorrect timing L Fouled, shorted or improperly gapped plugs 2. Incorrect valve clearance 3. Leaky intake and exhaust valves 4. Leaky cylinders 1. Vacuum leaks: L PCV hoses L Intake manifold L Throttle body L Brake booster line 2. Lean mixture causing misfire 1. Restricted air filter 2.Faulty SFI systems: L Faulty pressure regulator L Defective ECT sensor L Faulty ECM L Faulty injectors L Faulty throttle position sensor L Faulty MAF meter
Low
High
Rough idle (fluctuating HC reading)
High
High
Rough idle (Black smoke from exhaust)
Author :
Date :
1575
EM-3
ENGINE MECHANICAL COMPRESSION
COMPRESSION
EM0KR-09
INSPECTION
HINT: If there is a lack of power, excessive oil consumption or poor fuel economy, measure the compression pressure. 1. WARM UP AND STOP ENGINE Allow the engine to warm up to the normal operating temperature. 2. REMOVE SPARK PLUGS (See page IG-1 )
Compression Gauge
3. (a) (b) (c)
CHECK CYLINDER COMPRESSION PRESSURE Insert a compression gauge into the spark plug hole. Fully open the throttle. While cranking the engine, measure the compression pressure.
A04458
HINT: Always use a fully charged battery to obtain the engine speed at 250 rpm or more. (d) Repeat steps (a) to (c) for each cylinder. NOTICE: This measurement must be done as quickly as possible. Compression pressure: 1,324 kPa (13.5 kgf/cm2, 192 psi) or more Minimum pressure: 981 kPa (10.0 kgf/cm2, 142 psi) Difference between each cylinder: 98 kPa (1.0 kgf/cm2, 14 psi) or less (e) If the cylinder compression in one or more cylinders is lower than the specification, pour a small amount of engine oil into the cylinder through the spark plug hole and repeat steps (a) to (c) for the cylinders. L If adding oil helps the compression, chances are that the piston rings and/or cylinder bore are worn or damage. L If the pressure stays low, a valve may be sticking or the seating is improper, or there may be leakage past the gasket. 4. REINSTALL SPARK PLUGS (See page IG-1 )
Author :
Date :
1576
EM-86
ENGINE MECHANICAL CYLINDER BLOCK
CYLINDER BLOCK
EM0E9-15
COMPONENTS
Oil Cooler Pipe Bracket for A/T Engine Wire Protector Ground Cable
Water Bypass Pipe z O-Ring Water Pump Engine Wire
Starter
45 (450, 33)
x5 Engine Mounting Bracket

36 (370, 27)
z Gasket Knock Sensor 2 Engine Coolant Drain Union Knock Sensor 1
Starter Cable Starter Connector Knock Sensor 2 Connector Engine Wire Knock Sensor 1 Connector
30.5 (310, 22)
Oil Pump z O-Ring
z Crankshaft Front Oil Seal

15.5 (160, 11)
L Engine Coolant Drain Union z Gasket Crankshaft Position Sensor Connector

7.5 (80, 66 in.lbf)
Engine Wire Cover
Engine Mounting Bracket

7.5 (80, 66 in.lbf)
Oil Strainer Oil Pressure Sender Gauge Connector Clamp z Tape

28 (290, 31)
No.1 Oil Pan

7.5 (80, 66 in.lbf)
7.5 (80, 66 in.lbf)
x8
28 (290, 31)
28 (290, 31) 7.5 (80, 66 in.lbf)
Oil Pan Baffle Plate
No.2 Oil Pan

7.5 (80, 66 in.lbf)
x 20
Nm (kgfcm, ftlbf) : Specified torque z Non-reusable part L Precoated part
z Gasket Drain Plug
A05111
Author :
Date :
1659
EM-87
No.1 Piston Ring No.2 Piston Ring Oil Ring Side Rail Expander Side Rail
Piston z Snap Ring z Snap Ring Piston Pin Connecting Rod z Connecting Rod Bushing
Connecting Rod Bearing

See page EM-107 1st 24.5 (250, 18) 2nd Turn 90
Connecting Rod Cap
z O-Ring
z Crankshaft Rear Oil Seal
Cylinder Block
x7
Rear Oil Seal Retainer
Upper Crankshaft Thrust Washer
Upper Main Bearing
Crankshaft
Lower Main Bearing
Lower Crankshaft Thrust Washer
Main Bearing Cap
See page EM-107 1st 27 (275, 20) 2nd Turn 90
Nm (kgfcm, ftlbf) : Specified torque z Non-reusable part

A04847
Author :
Date :
1660
EM-88
EM0L6-03
DISASSEMBLY
1. 2. 3. INSTALL ENGINE TO ENGINE STAND REMOVE TIMING BELT AND PULLEYS (See page EM-15 ) REMOVE CYLINDER HEAD (See page EM-35 )
Pull Wire Clamp O-Ring
4. (a) (b) (c) (d) 5. 6.

A05112
REMOVE WATER BYPASS PIPE Disconnect the wire clamp (for knock sensor 1, 2) from the bracket of the water bypass pipe. Remove the bolt. Pull out the water bypass pipe from the water pump. Remove the O-ring from the water bypass pipe. REMOVE STARTER (See page ST-5 ) REMOVE KNOCK SENSORS (See page SF-55 )
LH Side
7. (a) (b)
DISCONNECT ENGINE WIRE FROM LH SIDE OF CYLINDER BLOCK Remove the 2 bolts and the engine wire cover from the LH side of the cylinder block. Remove the bolt, disconnect the bracket on the engine wire from the cylinder block.
A05110
RH Side
A05109
DISCONNECT ENGINE WIRE FROM RH SIDE OF CYLINDER BLOCK Remove the 2 bolts, and disconnect the 2 brackets on the engine wire from the cylinder block. 9. REMOVE OIL COOLER PIPE BRACKET FOR A/T Remove the bolt and bracket. 10. REMOVE ENGINE MOUNTING BRACKETS Remove the 4 bolts and the mounting bracket. Remove the 2 mounting brackets 11. REMOVE WATER PUMP (See page CO-6 ) 12. REMOVE NO.2 OIL PAN (See page LU-8 ) 13. REMOVE OIL PAN BAFFLE PLATE 14. REMOVE NO.1 OIL PAN (See page LU-8 ) 15. REMOVE OIL STRAINER 16. REMOVE OIL PUMP (See page LU-8 ) 17. REMOVE ENGINE COOLANT DRAIN UNIONS Remove the 2 drain unions.
8.
Author :
Date :
1661
EM-89
18. (a) (b) (c)

pry
REMOVE REAR OIL SEAL RETAINER Remove the 7 bolts. Using a screwdriver, ply off the oil seal retainer and the main bearing cap with a screwdriver. Remove the O-ring.
A05086
A05100
19. CHECK CONNECTING ROD THRUST CLEARANCE Using a dial indicator, measure the thrust clearance while moving the connecting rod back an a forth. Standard thrust clearance: 0.160 - 0.290 mm (0.0063 - 0.0138 in.) Maximum thrust clearance: 0.35 mm (0.0138 in.) If the thrust clearance is greater than the maximum, replace the connecting rod assembly(s). If necessary, replace the crankshaft. Connecting rod thickness: 22.880 - 22.920 mm (0.9008 - 0.9024 in.)
20. (a) (b)
REMOVE CONNECTING ROD CAPS AND CHECK OIL CLEARANCE Check the matchmarks on the connecting rod and cap to ensure correct reassembly. Remove the 2 connecting rod cap bolts.
A05104
(c)
Using the 2 removed connecting rod cap bolts, remove the connecting rod cap and the lower bearing by wiggling the connecting rod cap right and left.
A05105
HINT: Keep the lower bearing inserted with the connecting rod cap. (d) Clean the crank pin and the bearing. (e) Check the crank pin and the bearing for pitting and scratches. If the crank pin or the bearing is damaged, replace the bearings. If necessary, replace the crankshaft.
Author : Date : 1662
EM-90
Plastigage
(f)
Lay a strip of plastigage across the crank pin.
A05102
Install the connecting rod cap with the 2 bolts. (See page EM-107 ) NOTICE: Do not turn the crankshaft. (h) Remove the 2 bolts, the connecting rod cap and the lower bearing. (See procedure (b) and (c) above)
(g)
A05101
(i)
Measure the plastigage at its widest point. Standard oil clearance: 0.027 - 0.053 mm (0.0011 - 0.0021 in.) Maximum oil clearance: 0.065 mm (0.0026 in.) If the oil clearance is greater than the maximum, replace the bearings. If necessary, replace the crankshaft.
A05103
Number Mark No.4 No.3 No.1 No.2
HINT: If using a standard bearing, replace it with the one having the same number. If the number of the bearing cannot be determined, sum up the numbers imprinted on the connecting rod cap and the crankshaft, then select the one with the same number as the total. There are 6 sizes of standard bearings, marked 2, 3, 4, 5, 6 and 7.
Number mark Connecting rod cap 1 Crankshaft 1 Use bearing 2 1 2 3 2 1 1 3 2 2 4 3 1 2 3 3 2 5 4 1 3 4 3 2 6 4 3 7
Number Mark Number Mark
EXAMPLE: Connecting rod cap 3 + Crankshaft 1 = Total number 4 (Use bearing 4)
A05852 A05087 A05853
A05175
Author :
Date :
1663
EM-91
Reference Connecting rod big end inside diameter:

Mark 1 Mark 2 Mark 3 Mark 4 55.000 - 55.006 mm (2.1654 - 2.1656 in.) 55.006 - 55.012 mm (2.1656 - 2.1658 in.) 55.012 - 55.018 mm (2.1658 - 2.1661 in.) 55.018 - 55.024 mm (2.1661 - 2.1663 in.)
Crankshaft crank pin diameter:

Mark 1 Mark 2 Mark 3 51.994 - 52.000 mm (2.0470 - 2.0472 in.) 51.988 - 51.994 mm (2.0468 - 2.0470 in.) 51.982 - 51.988 mm (2.0465 - 2.0468 in.)
Standard sized bearing center wall thickness:

Mark 2 Mark 3 Mark 4 Mark 5 Mark 6 Mark 7 1.484 - 1.487 mm (0.0584 - 0.0585 in.) 1.487 - 1.490 mm (0.0585 - 0.0587 in.) 1.490 - 1.493 mm (0.0587 - 0.0588 in.) 1.493 - 1.496 mm (0.0588 - 0.0589 in.) 1.496 - 1.499 mm (0.0589 - 0.0590 in.) 1.499 - 1.502 mm (0.0590 - 0.0591 in.)
(j) 21. (a) (b) HINT:

Ridge Reamer L
A04852
Completely remove the plastigage. REMOVE PISTON AND CONNECTING ROD ASSEMBLIES Using a ridge reamer, remove all the carbon from the top of the cylinder. Push the piston, connecting rod assembly and upper bearing through the top of the cylinder block. Keep the bearings, the connecting rod and the cap together. Arrange the piston and connecting rod assemblies in correct order.
A05096
22. CHECK CRANKSHAFT THRUST CLEARANCE Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver. Standard thrust clearance: 0.020 - 0.220 mm (0.0008 - 0.0087 in.) Maximum thrust clearance: 0.30 mm (0.0118 in.) If the thrust clearance is greater than the maximum, replace the thrust washers as a set. Thrust washer thickness: 2.440 - 2.490 mm (0.0961 - 0.0980 in.)
EM-92
7 9 1 5
23. (a)
4 8
REMOVE MAIN BEARING CAPS AND CHECK OIL CLEARANCE Evenly loosen and remove the 10 main bearing cap bolts a little at time for several times, in the sequence shown.
6 2
10
A05095
(b)
A05093
Using 2 screwdrivers, pry out the main bearing cap, and remove the 5 main bearing caps, the 5 lower bearings and the 2 lower thrust washers (No.3 main bearing cap only). NOTICE: Be careful not to damage the cylinder block. HINT: L Keep the lower bearing and the main bearing cap together. L Arrange the main bearing caps and lower thrust washers in correct order. (c) Lift out the crankshaft. HINT: Keep the upper bearings and the upper thrust washers together with the cylinder block. (d) Clean each main journal and bearing. (e) Check each main journal and bearing for pitting and scratches. If the journal or bearing is damaged, replace the bearings. If necessary, replace the crankshaft. (f) (g) Place the crankshaft on the cylinder block. Lay a strip of plastigage across each journal.
Plastigage
A05097
Install the main bearing caps. (See page EM-107 ) NOTICE: Do not turn the crankshaft. (i) Remove the main bearing caps. (See procedure (a) and (b) above)
(h)
A05095
Author :
Date :
1665
EM-93
(j)
Measure the plastigage at its widest point. Standard clearance: 0.040 - 0.058 mm (0.0016 - 0.0023 in.) Maximum clearance: 0.070 mm (0.0028 in.) If the oil clearance is greater than the maximum, replace the bearings. If necessary, replace the crankshaft.
A05098
No.3
No.4 No.5 Number Mark No.2 No.1 Number Mark
HINT: If using a standard bearing, replace it with the one having the same number. If the number of the bearing cannot be determined, sum up the numbers imprinted on the cylinder block and the crankshaft, then refer to the table below for the appropriate bearing number. There are 5 sizes of the standard bearings. For No.1 and No.5 position bearings, use bearings marked 3, 4, 5, 6 and 7. For others position bearings, use bearings marked 1, 2, 3, 4 and 5.
No.1, No.5: Use bearing 3 4 5 6 7
No.5 No.2 No.1 No.3 No.4 Number Mark

A05176
Cylinder block (A) + Crankshaft (B)
0 6 12 18 24
-5 - 11 - 17 - 23 - 28
A05089 A05088 A05090
EXAMPLE: Cylinder block 08 + Crankshaft 06 = Total number 14 (Use bearing 5) Others: 0 6 12 18 24 -5 - 11 - 17 - 23 - 28 Use bearing 1 2 3 4 5
Cylinder block (A) + Crankshaft (B)
EXAMPLE: Cylinder block 08 + Crankshaft 06 = Total number 14 (Use bearing 3)
Reference Cylinder block main journal bore diameter (A):

Mark 00 Mark 01 Mark 02 Mark 03 Mark 04 Mark 05 Mark 06 Mark 07 2004 LAND CRUISER (RM1071U) 72.000 mm (2.8346 in.) 72.001 mm (2.8347 in.) 72.002 mm (2.8347 in.) 72.003 mm (2.8348 in.) 72.004 mm (2.8348 in.) 72.005 mm (2.8348 in.) 72.006 mm (2.8349 in.) 72.007 mm (2.8349 in.)
Author :
Date :
1666
EM-94
ENGINE MECHANICAL CYLINDER BLOCK 72.008 mm (2.8350 in.) 72.009 mm (2.8350 in.) 72.010 mm (2.8350 in.) 72.011 mm (2.8351 in.) 72.012 mm (2.8351 in.) 72.013 mm (2.8352 in.) 72.014 mm (2.8352 in.) 72.015 mm (2.8352 in.) 72.016 mm (2.8353 in.)
Mark 08 Mark 09 Mark 10 Mark 11 Mark 12 Mark 13 Mark 14 Mark 15 Mark 16
Crankshaft main journal diameter (B):

Mark 00 Mark 01 Mark 02 Mark 03 Mark 04 Mark 05 Mark 06 Mark 07 Mark 08 Mark 09 Mark 10 Mark 11 Mark 12 67.000 mm (2.6378 in.) 66.999 mm (2.6378 in.) 66.998 mm (2.6377 in.) 66.997 mm (2.6377 in.) 66.996 mm (2.6376 in.) 66.995 mm (2.6376 in.) 66.994 mm (2.6376 in.) 66.993 mm (2.6375 in.) 66.992 mm (2.6375 in.) 66.991 mm (2.6374 in.) 66.990 mm (2.6374 in.) 66.989 mm (2.6374 in.) 66.988 mm (2.6373 in.)
Standard bearing center wall thickness: No.1 and No.5

Mark 3 Mark 4 Mark 5 Mark 6 Mark 7 2.481 - 2.484 mm (0.0977 - 0.0978 in.) 2.484 - 2.487 mm (0.0978 - 0.0979 in.) 2.487 - 2.490 mm (0.0979 - 0.0980 in.) 2.490 - 2.493 mm (0.0980 - 0.0981 in.) 2.493 - 2.496 mm (0.0981 - 0.0983 in.)
Others:
Mark 1 Mark 2 Mark 3 Mark 4 Mark 5 2.481 - 2.484 mm (0.0977 - 0.0978 in.) 2.484 - 2.487 mm (0.0978 - 0.0979 in.) 2.487 - 2.490 mm (0.0979 - 0.0980 in.) 2.490 - 2.493 mm (0.0980 - 0.0981 in.) 2.493 - 2.496 mm (0.0981 - 0.0983 in.)
(k)
Completely remove the plastigage.
Author :
Date :
1667
EM-95
24. (a) (b)
REMOVE CRANKSHAFT Lift up the crankshaft. Remove the 5 upper main bearings and the 2 upper thrust washers from the cylinder block.
HINT: Arrange the main bearing caps, bearings and thrust washers in correct order for installation.
25. CHECK FIT BETWEEN PISTON AND PISTON PIN Try to move the piston back and forth on the piston pin. If any movement is felt, replace the piston and pin as a set.
A04862
26. (a)
(b) HINT: Arrange the piston rings in correct order for installation.
REMOVE PISTON RINGS Using a piston ring expander, remove the 2 compression rings. Remove the 2 side rails and the oil ring by hand.
A04873
27. (a)
DISCONNECT CONNECTING ROD FROM PISTON Using a small screwdriver, pry out the 2 snap rings.
A04860
(b)
Gradually heat the piston to approx. 60C (140F).
A04887
Author :
Date :
1668
EM-96
(c)
Using a plastic-faced hammer and a brass bar, lightly tap out the piston pin and the pin and remove the connecting rod. The piston and the pin are the set. Arrange the pistons, the pins, the rings, the connecting rods and the bearings in correct order for installation.
HINT:
L L
A04888
Author :
Date :
1669
EM-97
EM0EB-13
INSPECTION
1. (a) (b) CLEAN CYLINDER BLOCK Using a gasket scraper, remove all the gasket material from the top surface of the cylinder block. Using a soft brush and solvent, thoroughly clean the cylinder block.
A04849
2. (a)
INSPECT CYLINDER BLOCK Inspect for flatness. Using a precision straight edge and a feeler gauge, measure the surfaces contacting the cylinder head and main bearing cap for a warp. Maximum warpage: 0.07 mm (0.0028 in.) If the warp is greater than the maximum, replace the cylinder block.
Cylinder Block Side
Main Bearing Cap Side
A04850 A04210 A04212
A05178
(b) Visually check the cylinder for vertical scratches. If deep scratches are found, rebore all the 8 cylinders and replace all the 8 pistons (See page EM-104 ). If necessary, replace the cylinder block.
A04853
Author :
Date :
1670
EM-98
No.2
No.4
No.6
No.8
Front
(c) Inspect the cylinder bore diameter. HINT: 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.
No.1
No.3
No.4
No.5
A04211
: Mark 1, 2 or 3
11
Thrust Direction Axial Direction

STD
Front
2 2
Using a cylinder gauge, measure the cylinder bore diameter at positions A, B and C in the thrust and axial directions. Standard diameter:
Mark 1 1 Mark 2 2 Mark 3 94.002 - 94.010 mm (3.7009 - 3.7012 in.) 94.010 - 94.023 mm (3.7012 - 3.7017 in.) 94.023 - 94.031 mm (3.7017 - 3.7020 in.)
A B C
10 mm (0.39 in.)
Maximum diameter: 94.23 mm (3.7098 in.)

STD 94.231 mm (3.7099 in.) 94.731 mm (3.7296 in.)
10 mm (0.39 in.)
O/S 0.50
If the diameter is greater than the maximum, rebore all the 8 cylinders and replace all the 8 pistons (See page EM-104 ). If necessary, replace the cylinder block.
A04262 A04851
A05181
(d) Remove the cylinder ridge. If the wear is less than 0.2 mm (0.008 in.), using a ridge reamer, grind the top of the cylinder.
Ridge Reamer
A04852
(e)
Using vernier calipers, measure the thread outside diameter of the main bearing cap bolt. Standard diameter: 10.760 - 10.970 mm (0.4236 - 0.4319 in.) Minimum diameter: 10.40 mm (0.4094 in.) If the diameter is less than the minimum, replace the cap bolt.
50 - 64 mm (1.97 - 2.52 in.)

A05138
Author :
Date :
1671
EM-99
3. (a)
CLEAN PISTON Using a gasket scraper, remove the carbon from the piston top.
A04877
(b)
Using a groove cleaning tool or broken ring, clean the piston ring grooves.
A04878
(c) Using solvent and a brush, thoroughly clean the piston. NOTICE: Do not use a wire brush.
A04879
Mark 1, 2 or 3 LH Piston
30.75 mm
4. INSPECT PISTON AND CONNECTING ROD (a) Inspect the piston oil clearance. HINT: There are 3 sizes of the standard piston diameter, marked 1, 2 and 3 accordingly. The mark is stamped on the piston top. (1) Using a micrometer, measure the piston diameter at right angles to the piston pin center line, 30.75 mm (1.2106 in.) from the piston head. Piston diameter:
STD Mark 1 1 Mark 2 2 Mark 3 93.902 - 93.912 mm (3.6969 - 3.6973 in.) 93.912 - 93.920 mm (3.6973 - 3.6976 in.) 93.920 - 93.930 mm (3.6976 - 3.6980 in.) 94.402 - 94.430 mm (3.7166 - 3.7177 in.)
Mark 1, 2 or 3
RH Piston
O/S 0.50
(2) (3)
Measure the cylinder bore diameter in the thrust directions. (See step 2 above) Subtract the piston diameter from the cylinder bore diameter.
A04874 A04885
A05180
Author :
Date :
1672
EM-100
Standard oil clearance: 0.090 - 0.111 mm (0.0035 - 0.0044 in.) Maximum oil clearance: 0.13 mm (0.0051 in.) If the oil clearance is greater than the maximum, replace all the 8 pistons and rebore all the 8 cylinders. (See page EM-104 ) If necessary, replace the cylinder block.
Cylinder Block
No.2 No.4 No.6 No.8
Front
HINT Use new cylinder block: L Use a piston with the same number mark as the cylinder diameter marked on the cylinder block. L The shape of the piston varies for the LH and the RH banks. The LH piston is marked as LH and 2L, and the RH piston as RH and 2R.
No.1 :
No.3
No.5
No.7
Mark 1, 2 or 3 Mark 1, 2 or 3
LH Piston
RH Piston
A04211 A04875 A04885
Mark 1, 2 or 3
A05179
(b)
Inspect the piston ring groove clearance. Using a feeler gauge, measure the clearance between new piston ring and the wall of the ring groove. Ring groove clearance:
No.1 No.2 0.030 - 0.080 mm (0.0012 - 0.0031 in.) 0.030 - 0.070 mm (0.0012 - 0.0028 in.)
If the clearance is not as specified, replace the piston.

A04880
Author :
Date :
1673
EM-101
(c)
Inspect the piston ring end gap. (1) Insert the piston ring into the cylinder bore. (2) Using a piston, push the piston ring to a little beyond the bottom of the ring travel, 105 mm (4.13 in.) from the top of the cylinder block.
105 mm
A04872
(3) Using a feeler gauge, measure the end gap. Standard end gap:
No.1 No.2 Oil (Side rail) 0.300 - 0.500 mm (0.0118 - 0.0197 in.) 0.400 - 0.650 mm (0.0157 - 0.0256 in.) 0.130 - 0.480 mm (0.0051 - 0.0189 in.)
Maximum end gap:

No.1
EM7639
1.10 mm (0.0433 in.) 1.20 mm (0.0472 in.) 1.15 mm (0.0453 in.)
No.2 Oil (Side rail)
If the end gap is greater than the maximum, replace the piston ring. If the end gap is greater than the maximum, even with a new piston ring, rebore all the 8 cylinders (See page EM-104 ) or replace the cylinder block.
(d)
60C
Inspect the piston pin fit. At 60C (140F), you should be able to push the piston pin into the piston pin hole with your thumb.
A04048
(e)
Using a rod aligner and the feeler gauge, check the connecting rod alignment. (1) Check for bend. Maximum bend: 0.05 mm (0.0020 in.) per 100 mm (3.94 in.) If bend is greater than maximum, replace the connecting rod assembly.
Z14454
Author :
Date :
1674
EM-102
(2) Check for twist Maximum twist: 0.15 mm (0.0059 in.) per 100 mm (3.94 in.) If twist is greater than the maximum, replace the connecting rod assembly.
Z14455
(f)
Inspect the piston pin oil clearance. (1) Using a caliper gauge, measure the inside diameter of the connecting rod bushing. Bushing inside diameter: 22.005 - 22.014 mm (0.8663 - 0.8667 in.)
EM6525
EM0227
Using a micrometer, measure the piston pin diameter. Piston pin diameter: 21.997 - 22.009 mm (0.8660 - 0.8664 in.) (3) Subtract the piston pin diameter from the bushing inside diameter. Standard oil clearance: 0.005 - 0.011 mm (0.0002 - 0.0004 in.) Maximum oil clearance: 0.05 mm (0.0020 in.) If the oil clearance is greater than the maximum, replace the bushing. If necessary, replace the piston and the piston pin as a set.
(2)
(g)
Tension Portion
A04223
Using vernier calipers, measure the tension portion of the connecting rod bolt. Standard diameter: 7.200 - 7.300 mm (0.2835 - 0.2874 in.) Minimum diameter: 7.00 mm (0.2756 in.) If the diameter is less than the minimum, replace the bolt.
Author :
Date :
1675
EM-103
5. (a)
INSPECT CRANKSHAFT Inspect for circle runout. (1) Place the crankshaft on V-blocks. (2) Using a dial indicator, measure the circle runout at the center journal. Maximum circle runout: 0.08 mm (0.0031 in.) If the circle runout is greater than the maximum, replace the crankshaft.
A05121
(b)
Inspect the main journals and the crank pins. (1) Using a micrometer, measure the diameter of each main journal and crank pin. Main journal diameter: 66.988 - 67.000 mm (2.6373 - 2.6378 in.) Crank pin diameter: 51.982 - 52.000 mm (2.0465 - 2.0472 in.) If the diameter is not as specified, check the oil clearance (See page EM-88 ). If necessary, replace the crankshaft. (2) Check each main journal and crank pin for taper and out-of-round as shown. Maximum taper and out-of-round: 0.02 mm (0.0008 in.) If the taper and out-of-round is greater than the maximum, replace the crankshaft.
A05122 A05854
A05169
Author :
Date :
1676
EM-107
EM0L8-03
REASSEMBLY
HINT:
L L L
1. (a)
A04861
Thoroughly clean all parts to be assembled. Before installing the parts, apply new engine oil to all sliding and rotating surfaces. Replace all gaskets, O-rings and oil seals with new parts. ASSEMBLE PISTON AND CONNECTING ROD Using a small screwdriver, install a new snap ring on one side of the piston pin hole. Gradually heat the piston to about 60C (140F).
(b)
60C
A04876
LH Piston Front Mark (1 Cavity)
(c) (d)
Outside Mark RH Piston
Coat the piston pin with engine oil. Position the piston front mark to the outside mark on the connecting rod as shown in the diagram. NOTICE: The installation directions of the piston and connecting rod are different for the LH and RH banks. The LH piston is marked with LH and 2L, the RH piston with RH and 2R. (e) Align the piston pin holes of the piston and connecting rod, and push in the piston pin with your thumb.
Front Mark (2 Cavities)
Outside Mark
A04882 A04886 A05182
(f)
Using a small screwdriver, install a new snap ring on the other side of the piston pin hole.
A04860
Author :
Date :
1680
EM-108
No.1
Code Mark 1R
2. (a) (b)
INSTALL PISTON RINGS Install the oil ring expander and the 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 1R 2R No.2
No.2 Code Mark 2R
A04213
LH Piston Lower Side Rail 60
No.2 Compression Expander 45
(c)
Position the piston rings so that the ring ends are as shown. NOTICE: Do not align the ring ends.
Front Mark 60 (1 Cavity) Upper Side Rail RH Piston Lower Side 60 Rail
45 No.1 Compression No.2 Compression Expander 45
Front Mark 60 (2 Cavities)

A04871 A04870
45 No.1 Compression
A05183
Upper Side Rail
3. (a) (b)
INSTALL BEARINGS Align the bearing claw with the groove of the connecting rod or the connecting cap. Install the bearings in the connecting rod and the connecting rod cap.
EM6484
No.1 and No.5 Upper
Others
Lower 22.5 mm 19.5 mm

A04846
4. INSTALL MAIN BEARINGS HINT: L Main bearings come in widths of 19.5 mm (0.768 in.) and 22.5 mm (0.886 in.). Install the 22.5 mm (0.886 in.) bearings in the No.1 and No.5 cylinder block journal positions with the main bearing cap. Install the 19.5 mm (0.768 in.) bearings in the other positions. L Upper bearings have an oil groove and an oil holes; lower bearings do not.
Author :
Date :
1681
EM-109
(a)
Align the bearing claw with the claw groove of the cylinder block, and push in the 5 upper bearings.
A04216
(b)
Align the bearing claw with the claw groove of the main bearing cap, and push in the 5 lower bearings.
HINT: A number is marked on each main bearing cap to indicate the installation position.
Mark 1, 2, 3, 4, or 5
A04214
5. INSTALL UPPER THRUST WASHERS Install the 2 thrust washers under the No.3 journal position of the cylinder block with the oil grooves facing outward. 6. PLACE CRANKSHAFT ON CYLINDER BLOCK
A04215
7. (a)
PLACE MAIN BEARING CAPS AND LOWER THRUST WASHERS ON CYLINDER BLOCK Install the 2 thrust washers on the No.3 bearing cap with the grooves facing outward.
A04217
(b) Install the 5 main bearing caps in their proper locations. 8. INSTALL MAIN BEARING CAP BOLTS HINT: L The main bearing cap bolts are tightened in 2 steps (steps (b) and (d)). L If any one of the main bearing cap bolts is broken or deformed, replace it.
A05091
Author :
Date :
1682
EM-1 10
2 6 10
(a)
7 3 1 5 9
A05095
Apply a light coat of engine oil on the threads and under the main bearing cap bolts. (b) Install and evenly tighten the 10 main bearing cap bolts a little at a time for several times as in the sequence shown. Torque: 27 Nm (275 kgfcm, 20 ftlbf) If any one of the main bearing cap bolts does not meet the torque specification, replace the main bearing cap bolt.
90 90 Front Painted Mark

A05094
(c) (d) (e) (f) 9.
Mark the front of the main bearing cap bolt with paint. Retighten the main bearing cap bolts by 90 in the numerical order shown. Check that the painted mark is now at a 90 angle to the front. Check that the crankshaft turns smoothly. CHECK CRANKSHAFT THRUST CLEARANCE (See page EM-88 )
10.
INSTALL PISTON AND CONNECTING ROD ASSEMBLES Using a piston ring compressor, push the correctly numbered piston and connecting rod assemblies into each cylinder with the front mark of the piston facing forward. NOTICE: The shape of the piston varies for the LH and RH banks. The LH piston is marked with LH and 2R, the RH piston with RH and 2R.
Front Mark (1 Cavity)
Front
LH Piston
Front Mark (2 Cavities)
Front
RH Piston
A04854 A04883 A04884
A05177
Author :
Date :
1683
EM-1 11
11. (a) (b)
PLACE CONNECTING ROD CAP ON CONNECTING ROD Match the numbered connecting rod cap with the connecting rod. Align the pin groove of the connecting rod cap with the pins of the connecting rod, and install the connecting rod cap.
A05106
LH Bank
(c) 12. HINT:

L L
Check that the outside mark of the connecting rod cap is facing in correct direction. INSTALL CONNECTING ROD CAP BOLTS The connecting rod cap bolts are tightened in 2 steps (steps (b) and (d)). If any one of the connecting rod cap bolts is broken or deformed, replace it.
Front
Outside Mark (Protrusion) RH Bank Front
Outside Mark (Protrusion)

A05107 A05108 A05174
(a)
Apply a light coat of engine oil on the threads and under the heads of the connecting rod cap bolts. (b) Install and alternately tighten the 2 connecting rod cap bolts a little at a time for several times. Torque: 24.5 Nm (250 kgfcm, 18 ftlbf) If any one of the connecting rod cap bolts does not meet the torque specification, replace the connecting rod cap bolts.
A05101
90 Front Painted Mark
90
(c) (d) (e) (f) 13.
Mark the front of the connecting cap bolt with paint. Retighten the cap bolts 90 as shown. Check that the painted mark is now at a 90 angle to the front. Check that the crankshaft turns smoothly. CHECK CONNECTING ROD THRUST CLEARANCE (See page EM-88 )
A05099
Author :
Date :
1684
EM-1 12
A B
14. (a)
(b)
A Seal Width 2 - 3 mm B
A04848
INSTALL REAR OIL SEAL RETAINER Remove any old packing (FIPG) material, and be careful not to drop any oil on the contact surfaces of the oil seal retainer and the cylinder block. L Using a razor blade and a gasket scraper, remove old FIPG from the seal surface. L Clean all the components to remove the redundant FIPG completely. L Clean sealing surfaces with solvent so that any residue does not remain on the seal. Apply seal packing to the oil seal retainer as shown in the illustration. Seal packing: Part No. 08826-00080 or equivalent L Install a nozzle that is cut to a 2 - 3 mm (0.08 - 0.12 in.) opening. L Parts must be assembled within 5 minutes after the seal packing application. Otherwise the material must be removed and the seal packing have to be reapplied. L Immediately remove the nozzle from the tube and reinstall the cap.
(c) (d)
New O-Ring
Install a new O-ring to the cylinder block. Install the oil seal retainer with the 7 bolts. Torque: 8.0 Nm (80 kgfcm, 71 in.lbf)
A04855
Seal Packing
15. (a)
INSTALL ENGINE COOLANT DRAIN UNIONS Apply seal packing to 2 or 3 threads from the end of the drain unions. Seal packing: Part No. 08826-00100 or equivalent
P12477
Author :
Date :
1685
EM-1 13
(b)
Install the 2 drain unions. Torque: 49 Nm (500 kgfcm, 36 ftlbf)
Port Front
A04856
HINT: After applying the specified torque, rotate the drain union clockwise until the drain port is facing forward. 16. INSTALL OIL PUMP (See page LU-15 ) 17. INSTALL OIL STRAINER (See page LU-15 ) 18. INSTALL NO.1 OIL PAN (See page LU-15 ) 19. INSTALL OIL PAN BAFFLE PLATE (See page LU-15 ) 20. INSTALL NO.2 OIL PAN (See page LU-15 ) 21. INSTALL WATER PUMP (See page CO-8 ) 22. INSTALL ENGINE MOUNTING BRACKETS Install the mounting bracket with the 4 bolts. Install the 2 mounting brackets. Torque: 36 Nm (370 kgfcm, 27 ftlbf)
LH Side
23. (a) (b)
INSTALL ENGINE WIRE TO LH SIDE OF CYLINDER BLOCK Install the bracket on the engine wire with the bolt. Install the engine wire cover with the 2 bolts.
A05110
RH Side
24.
INSTALL ENGINE WIRE TO RH SIDE OF CYLINDER BLOCK Install the 2 brackets on the engine wire with the 2 bolts. 25. INSTALL OIL COOLER PIPE BRACKET FOR A/T Install the bracket with the bolt. 26. INSTALL KNOCK SENSORS (See page SF-55 ) 27. INSTALL STARTER (See page ST-17 )
A05109
Push Wire Clamp
28. (a) (b) (c) (d) (e)

A05132
New O-Ring
29.
INSTALL WATER BYPASS PIPE Install a new O-ring to the water bypass pipe. Apply soapy water to the O-ring. Push the water bypass pipe end into the pipe hole of the water pump. Install the water bypass pipe with the bolt. Torque: 18 Nm (185 kgfcm, 13 ftlbf) Install the wire clamp to the bracket of the water bypass pipe. INSTALL CYLINDER HEADS (See page EM-59 )
EM-1 14
30. 31.
INSTALL TIMING BELT AND PULLEYS (See page EM-22 ) DISCONNECT ENGINE FROM ENGINE STAND
Author :
Date :
1687
EM-104
EM0L7-05
Sized Mark LH Piston
REPLACEMENT
1. HINT:
L L
REPLACE OVERSIZED (O/S) PISTONS FOR CYLINDER BORING Bore all the 8 cylinders to the oversized piston outside diameter. Replace all the piston rings with the ones to match the oversized pistons. Keep 8 new O/S pistons. O/S 0.50 piston diameter: 94.402 - 94.430 mm (3.7166 - 3.7177 in.)
(a)
Sized Mark RH Piston
A04874 A04885
A05180
HINT: The shape of the piston varies for the LH and RH banks. The LH piston is marked with LH and 2L, the RH piston with RH and 2R. (b) Using a micrometer, measure the piston diameter at right angles to the piston pin center line, 30.75 mm (1.2106 in.) from the piston head. (c) Calculate the amount for each cylinder to be rebored as follows: Size to be rebored = P + C - H P = Piston diameter C = Piston clearance: 0.090 - 0.111 mm (0.0035 - 0.0044 in.) H = Allowance for honing: 0.02 mm (0.0008 in.) or less (d) Bore and hone the cylinders to calculated dimensions. Maximum honing: 0.02 mm (0.0008 in.) NOTICE: Excess honing will destroy the finished roundness. 2. (a) REPLACE CONNECTING ROD BUSHINGS Using SST and a press, press out the bushing. SST 09222-30010
SST
P20665
(b) (c)
Oil Hole
Align the oil holes of a new bushing and the connecting rod. Using SST and a press, press in the bushing. SST 09222-30010
P20666
Author :
Date :
1677
EM-105
(d)
Using a pin hole grinder, hone the bushing to obtain the standard specified clearance (See page EM-97 ) between the bushing and piston pin.
P20667
(e)
Check the piston pin fit at normal room temperature. Coat the piston pin with engine oil, and push it into the connecting rod with your thumb.
P20668
3. REPLACE CRANKSHAFT FRONT OIL SEAL HINT: There are 2 methods ((a) and (b)) to replace the oil seal. (a) If the oil pump is removed from the cylinder block: (1) Using a screwdriver, pry out the oil seal.
A04865
(2)
Using SST and a hammer, tap in a new oil seal until its surface is flush with the oil pump body edge. SST 09316-6001 1 (09316-00011) (3) Apply MP grease to the oil seal lip.
SST
A04866
(b)
If the oil pump is installed to the cylinder block: (1) Using a knife, cut off the oil seal lip. (2) Using a screwdriver, pry out the oil seal. NOTICE: Be careful not to damage the crankshaft. Tape up the screwdriver tip.
Cut Position
A04863
Author :
Date :
1678
EM-106
(3) (4)
Apply MP grease to a new oil seal lip. Using SST and a hammer, tap in the oil seal until its surface is flush with the oil pump body edge. SST 09316-6001 1 (09316-00011)
SST
A04864
4. REPLACE CRANKSHAFT REAR OIL SEAL HINT: There are 2 methods ((a) and (b)) to replace the oil seal. (a) If the rear oil seal retainer is removed from the cylinder block: (1) Using a screwdriver and hammer, tap out the oil seal.
A04868
(2)
Using SST and a hammer, tap in a new oil seal until its surface is flush with the rear oil seal retainer edge. SST 09223-56010 (3) Apply MP grease to the oil seal lip.
SST
A04867
(b)
If the rear oil seal retainer is installed to the cylinder block: (1) Using a knife, cut off the oil seal lip. (2) Using a screwdriver, pry out the oil seal. NOTICE: Be careful not to damage the crankshaft. Tape up the screwdriver tip.
Cut Position
A04858
SST
(3) (4)
Apply MP grease to a new oil seal lip. Using SST and a hammer, tap in the oil seal until its surface is flush with the rear oil seal retainer edge. SST 09223-56010
A04859
Author :
Date :
1679
EM-28
ENGINE MECHANICAL CYLINDER HEAD
CYLINDER HEAD
EM1V7-01
COMPONENTS
V-Bank Cover A/C Discharge Tube Clamp Clamp Fuel Return Hose
Wire Clamp Bracket P/S Air Hose EVAP Hose Intake Air Connector Air Hose Bracket Radiator Reservoir Tank
5.0 (50, 43 in.lbf)
Fan Shroud
Lower Radiator Hose

18 (185, 13)
A/T Oil Cooler Hose
Radiator Assembly
Fan Pulley
Generator Drive Belt
Fan w/ Fluid Coupling

20 (200, 15)
A/C Compressor Connector A/C Compressor A/T Oil Cooler Hose

49 (500, 36)
x8 Nm (kgfcm, ftlbf) : Specified torque
Engine Under Cover No.1
A09750
Author :
Date :
1601
EM-29
62 (632, 46)
PS Pump
Heated Oxygen Sensor (Bank 2 Sensor 1)
Oil Dipstick and Guide for A/T L
L Gasket L Gasket
20 (200, 14)
40 (400, 30)
Heated Oxygen Sensor (Bank 1 Sensor 1) L Gasket L Gasket L

20 (200, 14)
62 (632, 46)
RH Front Exhaust Pipe
L Gasket
L L Gasket
40 (400, 30)
LH Front Exhaust Pipe Nm (kgfcm, ftlbf) : Specified torque L Non-reusable part

62 (632, 46)
A19471
Author :
Date :
1602
EM-30
RH No. 3 Timing Belt Cover
7.5 (80, 66 in.lbf)
No. 2 Timing Belt Cover

16 (160, 12)
Drive Belt Idler Pulley

39 (400, 29)
Cover Plate Camshaft Position Sensor Connector
Wire Grommet Engine Wire Oil Cooler Pipe Nm (kgfcm, ftlbf) : Specified torque
LH No. 3 Timing Belt Cover Camshaft Position Sensor
7.5 (80, 16 in.lbf)
A04460
RH Camshaft Timing Pulley LH Camshaft Timing Belt Pulley Timing Belt
108 (1,100, 80)
245 (2,500, 181) 16 (160, 12)
Dust Boot
32 (330, 24)
Timing Belt Tensioner

26 (270, 19)
A04327
Nm (kgfcm, ftlbf) : Specified torque

Fan Bracket
Author :
Date :
1603
EM-31
EVAP Hose V-Bank Cover Bracket
EVAP Pipe EVAP Hose
Rear Water Bypass Joint V-Bank Cover Bracket
Engine Wire
Engine Wire
Heater Hose
L Gasket PS Hose V-Bank Cover Throttle Control Connector Bracket Engine Wire
Injection Connector Fuel Return Hose VSV Connector for EVAP EVAP VSV Hose Fuel Inlet Hose
Water Sender Gauge
Water Bypass Hose
L Gasket
Wire Bracket ECT Sensor Connector
Engine Wire Heater Hose Ignition Coil Connector
Water Bypass Hose L O-Ring L Gasket Engine Wire
Front Water Bypass Joint
Water Inlet and Inlet Housing Assembly
Ignition Coil
RH No.1 Timing Belt Rear Plate L Non-reusable part

LH No.1 Timing Belt Rear Plate

A19470
Author :
Date :
1604
EM-32
VSV for EVAP
18 (185, 13)
Upper Intake Manifold L Gasket
Throttle Body Assembly
L Gasket
Fuel Return Pipe

7.5 (80, 66 in.lbf)
Vacuum Hose Fuel Pressure Regulator L O-Ring RH Delivery Pipe
Fuel Return Hose

21 (214, 15)
Fuel Pressure Pulsation Damper

* 33 (340, 24) 39 (400, 29)
Spacer Spacer
39 (400, 29)
L Upper Gasket Lower Intake Manifold

39 (400, 29)
21 (214, 15)
L Gasket L Gasket Front Fuel Pipe L O-Ring L Grommet Injector L Insulator
L Lower Gasket LH Delivery Pipe
Spacer
A17674
Nm (kgfcm, ftlbf) : Specified torque L Non-reusable part * For use with SST
A19480
Author :
Date :
1605
EM-33
Spark Plug RH Cylinder Head Cover

7.5 (77, 66 in.lbf) 7.5 (77, 66 in.lbf)
L Spark Plug Tube Gasket
LH Cylinder Head Cover Bearing Cap Gasket Bearing Cap RH Intake Camshaft L Oil Seal RH Exhaust Camshaft Oil Seal Camshaft Gear Spring Engine Hanger Camshaft Sub Gear Wave Washer Semi-Circular Engine Wire Bracket Plug Camshaft Housing Plug Snap Ring Wave Washer Engine Hanger Camshaft Gear Spring Camshaft Sub Gear Camshaft Housing Plug Semi-Circular Plug Gasket
16 (160,12)
Snap Ring
Oil Feed Pipe LH Intake Camshaft Bearing Cap LH Exhaust Camshaft
RH Cylinder Head and Exhaust Manifold Assembly L RH Cylinder Head Gasket
Engine Wire Bracket LH Cylinder Head and Exhaust Manifold Assembly
Engine Wire Protector L LH Cylinder Head Gasket Heated Oxygen Sensor (Bank 2 Sensor 1) Connector Heated Oxygen Sensor (Bank 1 Sensor 1) Connector Nm (kgfcm, ftlbf) : Specified torque L Non-reusable part
2004 LAND CRUISER (RM1071U) See page EM-59 1st 32 (326, 24) 2nd Turn 90 3rd Turn 90
Oil Dipstick and Guide for Engine L O-Ring
A05561
Author :
Date :
1606
EM-34
RH Cylinder Head
L Gasket
Valve Lifter
44 (450, 32)
RH Exhaust Manifold Adjust Shim Keeper Spring Retainer Valve Spring Spring Seat L Oil Seal L Valve Guide Bushing Valve
7.5 (77, 66 in.lbf)
Heat Insulator
L Gasket RH Cylinder Head
LH Exhaust Manifold
Heat Insulator
7.5 (77, 66 in.lbf)
Nm (kgfcm, ftlbf) : Specified torque L Non-reusable part

A05527
Author :
Date :
1607
EM-44
EM0L1-08
SST
DISASSEMBLY
1. REMOVE VALVE LIFTERS AND SHIMS HINT: Arrange the valve lifters and the shims in correct order. 2. REMOVE VALVES (a) Using SST, compress the valve spring and remove the 2 keepers. SST 09202-70020 (b) Remove the spring retainer. (c) Remove the valve spring. (d) Remove the valve. (e) Remove the spring seat. HINT: Arrange the valves, the valve springs, the spring seats and the spring retainers incorrect order. (f) Using needle-nose pliers, remove the oil seal.
A03191
A03192
Author :
Date :
1617
EM-45
EM0L2-07
INSPECTION
1. (a) CLEAN TOP SURFACES OF PISTONS AND CYLINDER BLOCK Turn the crankshaft, and bring each piston to top dead center (TDC). Using a gasket scraper, remove all the carbon from the piston top surface.
A03194
(b)
Using a gasket scraper, remove all the gasket material from the cylinder block surface. (c) Using compressed air, blow carbon and oil from the bolt holes. CAUTION: Protect your eyes when using high pressure compressed air.
A03193
2. REMOVE GASKET MATERIAL Using a gasket scraper, remove all the gasket material from the cylinder block contact surface. NOTICE: Be careful not to scratch the cylinder block contact surface.
EM6323
3. CLEAN COMBUSTION CHAMBERS Using a wire brush, remove all the carbon from the combustion chambers. NOTICE: Be careful not to scratch the cylinder block contact surface.
EM6324
4. CLEAN VALVE GUIDE BUSHINGS Using a valve guide bushing brush and solvent, clean all the guide bushings.
P21861
Author :
Date :
1618
EM-46
5. CLEAN CYLINDER HEAD Using a soft brush and solvent, thoroughly clean the cylinder head.
EM6325
6. INSPECT FOR FLATNESS Using a precision straight edge and a feeler gauge, measure the surfaces contacting the cylinder block and the manifolds for a warp. Maximum warpage: 0.10 mm (0.0039 in.) If the warp is greater than maximum, replace the cylinder head.
A05592
7. INSPECT FOR CRACKS Using a dye penetrate, check the combustion chamber, the intake ports, the exhaust ports and the cylinder head surface for cracks. If there is a crack, replace the cylinder head.
EM6327
8. (a) (b)
CLEAN VALVES Using a gasket scraper, chip off any carbon from the valve head. Using a wire brush, thoroughly clean the valve.
EM0580
Author :
Date :
1619
EM-47
9. (a)
INSPECT VALVE STEMS AND GUIDE BUSHINGS Using a caliper gauge, measure the inside diameter of the guide bushing. Bushing inside diameter: 5.510 - 5.530 mm (0.2169 - 0.2177 in.)
P21862
(b)
Z00052
Using a micrometer, measure the diameter of the valve stem. Valve stem diameter: Intake 5.470 - 5.485 mm (0.2154 - 0.2159 in.) Exhaust 5.465 - 5.480 mm (0.2152 - 0.2157 in.) (c) Subtract the valve stem diameter measurement from the guide bushing inside diameter measurement. Standard oil clearance: Intake 0.025 - 0.060 mm (0.0010 - 0.0024 in.) Exhaust 0.030 - 0.065 mm (0.0012 - 0.0026 in.) Maximum oil clearance: Intake 0.08 mm (0.0031 in.) Exhaust 0.10 mm (0.0039 in.) If the clearance is greater than the maximum, replace the valve and the guide bushing. (See Page EM-55 )
10. (a) (b)
INSPECT AND GRIND VALVES Grind the valve enough to remove pits and carbon. Check that the valve is ground to the correct valve face angle. Valve face angle: 44.5
Z00054
Author :
Date :
1620
EM-48
(c)
Margin Thickness
EM0181
Check the valve head margin thickness. Standard margin thickness: IN 1.25 mm (0.049 in.) EX 1.40 mm (0.055 in.) Minimum margin thickness: 0.5 mm (0.020 in.) If the margin thickness is less than the minimum, replace the valve.
(d)
Overall Length
Check the valve overall length. Standard overall length: Intake: 95.05 mm (3.7421 in.) Exhaust: 95.10 mm (3.7441 in.) Minimum overall length: Intake: 94.55 mm (3.7224 in.) Exhaust: 94.60 mm (3.7244 in.) If the overall length is less than the minimum, replace the valve.
EM2534
(e) Check the surface of the valve stem tip for wear. If the valve stem tip is worn, resurface the tip with a grinder or replace the valve. NOTICE: Do not grind off to below the minimum.
EM0255
45 Carbide Cutter
11. (a)
INSPECT AND CLEAN VALVE SEATS Using a 45 carbide cutter, resurface the valve seats. Remove just enough metal to clean the seats.
EM6330
Author :
Date :
1621
EM-49
(b)
Width
Z00055
45
30
Check the valve seating position. Apply a light coat of prussian blue (or white lead) to the valve face. Lightly press the valve against the seat. Do not rotate valve. (c) Check the valve face and seat for the following: L If blue appears 360 around the face, the valve is concentric. If not, replace the valve. L If blue appears 360 around the valve seat, the guide and face are concentric. If not, resurface the seat. L Check that the seat contact is in the middle of the valve face with the following width: 1.0 - 1.4 mm (0.039 - 0.055 in.) If not, correct the valve seats as follows: L If the seating is too high on the valve face, use 30 and 45 cutters to correct the seat.
1.0 - 1.4 mm
Z03988
60
45
If the seating is too low on the valve face, use 60 and 45 cutters to correct the seat.
1.0 - 1.4 mm
Z03989
(d) (e)
Hand-lap the valve and valve seat with an abrasive compound. After hand-lapping, clean the valve and valve seat.
EM6331
Deviation
12. (a)
INSPECT VALVE SPRINGS Using a steel square, measure the deviation of the valve spring. Maximum deviation: 2.0 mm (0.079 in.) If the deviation is greater than the maximum, replace the valve spring.
EM0988
Author :
Date :
1622
EM-50
(b)
Using vernier calipers, measure the free length of the valve spring. Free length: 54.1 mm (2.130 in.) If the free length is not as specified, replace the valve spring.
EM0801
(c)
Using a spring tester, measure the tension of the valve spring at the installed length. Installed tension: 204 - 226 N (20.8 - 23.0 kgf, 45.9 - 50.7 lbf) at 35.0 mm (1.378 in.) If the installed tension is not as specified, replace the valve spring.
EM0281
13. (a) (b)
INSPECT CAMSHAFT FOR RUNOUT Place the camshaft on V-blocks. Using a dial indicator, measure the circle runout at the center journal. Maximum circle runout: 0.08 mm (0.0031 in.) If the circle runout is greater than the maximum, replace the camshaft.
A05912
EM2011
14. INSPECT CAM LOBES Using a micrometer, measure the cam lobe height. Standard cam lobe height: Intake: 41.94 - 42.04 mm (1.6512 - 1.6551 in.) Exhaust: 41.96 - 42.06 mm (1.6520 - 1.6559 in.) Minimum cam lobe height: Intake: 41.79 mm (1.6453 in.) Exhaust: 41.81 mm (1.6461 in.) If the cam lobe height is less than the minimum, replace the camshaft.
Author :
Date :
1623
EM-51
15. INSPECT CAMSHAFT JOURNALS Using a micrometer, measure the journal diameter. Journal diameter: 26.954 - 26.970 mm (1.0612 - 1.0618 in.) If the journal diameter is not as specified, check the oil clearance.
A05519
EM3322
Plastigage
16. INSPECT CAMSHAFT GEAR SPRING Using vernier calipers, measure the free distance between the spring ends. Free distance: 18.2 - 18.8 mm (0.712 - 0.740 in.) If the free distance is not as specified, replace the gear spring. 17. INSPECT CAMSHAFT BEARINGS Check that bearings for flaking and scoring. If the bearings are damaged, replace the bearing caps and cylinder head as a set. 18. INSPECT CAMSHAFT JOURNAL OIL CLEARANCE (a) Clean the bearing caps and the camshaft journals. (b) Place the camshafts on the cylinder head. (c) Lay a strip of plastigage across each of the camshaft journals.
A05520
(d)
Install the bearing caps. (See page EM-59 ) Torque: 16 Nm (160 kgfcm, 12 ftlbf) NOTICE: Do not turn the camshaft. (e) Remove the bearing caps.
A05522
Author :
Date :
1624
EM-52
(f)
Measure the Plastigage at its widest point. Maximum oil clearance: 0.10 mm (0.0039 in.) If the oil clearance is greater than the maximum, replace the camshaft. If necessary, replace the bearing caps and cylinder head as a set. (g) Completely remove the plastigage. (h) Remove the camshafts.
A05521
19. (a)
A05523
INSPECT CAMSHAFT THRUST CLEARANCE Install the camshaft. (See page EM-59 ) (b) Using a dial indicator, measure the thrust clearance as moving the camshaft back and forth. Standard thrust clearance: Intake 0.040 - 0.090 mm (0.0016 - 0.0035 in.) Exhaust 0.040 - 0.085 mm (0.0016 - 0.0033 in.) Maximum thrust clearance: 0.12 mm (0.0047 in.) If the thrust clearance is greater than the maximum, replace the camshaft. If necessary, replace the bearing caps and cylinder head as a set. (c) Remove the camshafts.
20. (a)
A05524
INSPECT CAMSHAFT GEAR BACKLASH Install the camshafts without installing the exhaust cam sub-gear and the front bearing cap. (See page EM-59 ) (b) Using a dial indicator, measure the backlash. Standard backlash: 0.020 - 0.200 mm (0.0008 - 0.0079 in.) Maximum backlash: 0.30 mm (0.0188 in.) If the backlash is greater than the maximum, replace the camshafts. (c) Remove the camshafts.
Author :
Date :
1625
EM-53
21. (a)
INSPECT VALVE LIFTERS AND LIFTER BORES Using a caliper gauge, measure the lifter bore diameter of the cylinder head. Lifter bore diameter: 31.000 - 31.016 mm (1.2205 - 1.2211 in.)
A03209
(b)
12.3 - 12.7 mm
A03201
Using a micrometer, measure the lifter diameter at the valve lifter center line, 12.3 - 12.7 mm (0.484 - 0.500 in.) from the valve lifter head. Lifter diameter: 30.966 - 30.976 mm (1.2191 - 1.2195 in.) (c) Subtract the lifter diameter from the lifter bore diameter. Standard oil clearance: 0.024 - 0.050 mm (0.0009 - 0.0020 in.) Maximum oil clearance: 0.07 mm (0.0028 in.) If the oil clearance is greater than the maximum, replace the lifter. If necessary, replace the cylinder head.
22. (a)
INSPECT INTAKE MANIFOLD Upper intake manifold: Using a precision straight edge and a feeler gauge, measure the surface contacting of the lower intake manifold for a warp. Maximum warpage: 0.15 mm (0.0059 in.) If the warp is greater than the maximum, replace the upper intake manifold.
A05499
Author :
Date :
1626
EM-54
Upper Intake Manifold Side
(b)
Lower intake manifold: Using a precision straight edge and a feeler gauge, measure the surface contacting of the cylinder head and the upper intake manifold for a warpage. Maximum warpage: 0.15 mm (0.0059 in.) If the warp is greater than the maximum, replace the lower intake manifold.
Cylinder Head Side
A05500
23. INSPECT EXHAUST MANIFOLD Using a precision straight edge and a feeler gauge, measure the surface contacting of the cylinder head for a warp. Maximum warpage: 0.50 mm (0.0197 in.) If the warp is greater than the maximum, replace the manifold.
A05501
Measuring Point
75 - 85 mm (2.95 - 3.35 in.)
24. INSPECT CYLINDER HEAD BOLTS Using vernier calipers, measure the thread outside diameter of the bolt. Standard outside diameter: 9.810 - 9.960 mm (0.3862 - 0.3921 in.) Minimum outside diameter: 9.700 mm (0.3819 in.) If the diameter is less than the minimum, replace the bolt.
A02827
Author :
Date :
1627
EM-59
EM1V9-01
INSTALLATION
1. INSTALL RH EXHAUST MANIFOLD TO CYLINDER HEAD (a) Place a new gasket on the cylinder head with the white painted marks facing the manifold side. NOTICE: Be careful of the installation direction.
A05594
White Painted Mark
(b)
(c)
Install the exhaust manifold with 8 new nuts. Evenly tighten the nuts a little at a time for several times. Torque: 44 Nm (450 kgfcm, 32 ftlbf) Install the heat insulator with the 4 bolts. Torque: 7.5 Nm (77 kgfcm, 66 in.lbf)
A05498
2.
INSTALL LH EXHAUST MANIFOLD TO CYLINDER HEAD (a) Place a new gasket on the cylinder head with the white painted marks facing the manifold side. NOTICE: Be careful of the installation direction.
White Painted Mark
A05595
(b)
(c)
Install the exhaust manifold with 8 new nuts. Evenly tighten the nuts a little at a time for several times. Torque: 44 Nm (450 kgfcm, 32 ftlbf) Install the heat insulator with the 4 bolts. Torque: 7.5 Nm (77 kgfcm, 66 in.lbf)
A05518
Author :
Date :
1632
EM-60
RH Cylinder Head
3. (a)
PLACE CYLINDER HEAD ON CYLINDER BLOCK Place 2 new cylinder head gaskets in position on the cylinder block.
2UR
LH Cylinder Head
HINT: On the rear side of the cylinder head gasket, there is a mark to distinguish the LH and RH banks, a 2UR for the RH bank and a 2UL for the LH bank. NOTICE: Be careful of the installation direction. (b) Place the 2 cylinder heads in position on the cylinder head gaskets.
2UL
A05563
RH Cylinder Head 10 4 2 5 7
LH Cylinder Head 3 9
Front 6 1
4. INSTALL CYLINDER HEAD BOLTS HINT: L The cylinder head bolts are tightened in 2 progressive steps (steps (c) and (e)). L If any cylinder head bolt is broken or deformed, replace it. (a) Apply a light coat of engine oil on the threads and under the heads of the cylinder head bolts. (b) Install the plate washer to the cylinder head bolt. (c) Install and evenly tighten the 10 cylinder head bolts on one side of the cylinder head a little at a time for several times as in the order shown, then do the other side as shown. Torque: 32 Nm (325 kgfcm, 24 ftlbf) If any one of the cylinder head bolts does not meet the torque specification, replace the cylinder head bolt.
10
A05714
Author :
Date :
1633
EM-61
RH Cylinder Head
NOTICE: Do not drop the plate washer of the cylinder head bolt into A area in the illustration. It will fall down to the oil pan through the cylinder head and the cylinder block.
LH Cylinder Head
A04473
90 180
(d) (e) (f) (g) 5.

A11159
Painted Mark
Mark the front of the cylinder head bolt head with paint. Retighten the cylinder head bolts by 90 only for the first time. Then retighten them by 90 further for the second time. Check that the painted mark is now at a 180 angle to the front. INSTALL SPARK PLUGS
6. (a)
ASSEMBLE EXHAUST CAMSHAFT Install the camshaft gear spring, the camshaft sub-gear and the wave washer.
HINT: Attach the pins on the gears to the gear spring ends.
A02888
(b)
Using snap ring pliers, install the snap ring.
A02861
Author :
Date :
1634
EM-62
(c) Mount the hexagon shaped part of the camshaft in a vise. NOTICE: Be careful not to damage the camshaft.
A02859
Service Bolt SST
Sub Gear
(d)
Main Gear
(e)
Using SST, align the holes of the camshaft main gear and sub-gear by turning camshaft sub-gear counterclockwise, and temporarily install a service bolt. SST 09960-10010 (09962-01000, 09963-00500) Align the gear teeth of the main gear and sub-gear, and tighten the service bolt.
Turn
A02889
Seal Packing
7. (a) (b)
INSTALL CAMSHAFT HOUSING PLUGS Remove any old packing (FIPG) material. Apply seal packing to the camshaft housing plug grooves. Seal packing: Part No. 08826-00080 or equivalent
A02890
(c)
Install the 2 camshaft housing plugs to the cylinder heads.
RH Cylinder Head
LH Cylinder Head
Front
A05502
Author :
Date :
1635
EM-63
8. INSTALL CAMSHAFTS NOTICE: Since the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being removed. Otherwise, excessive pressure is put on the cylinder head journal thrust, causing a burr on the journal and damage on the camshaft. To avoid this, follow the steps below. (a)
Timing Mark No. 2 Idler Pulley Bolt
Turn
A04336
Set the crankshaft pulley position. Turn the crankshaft pulley clockwise or counterclockwise, and put the timing mark of the crankshaft pulley in line with the centers of the crankshaft pulley bolt and the idler pulley bolt. NOTICE: Having the crankshaft pulley at the wrong angle can cause the piston head and the valve head to come into contact with each other when removing the camshaft, causing damage on them. So always set the crankshaft pulley at the correct angle. (b) Install the RH camshafts. (1) Apply MP grease to the thrust portion of the intake and exhaust camshafts. (2) Place the intake and exhaust camshafts. (3) Set the timing mark (1 dot mark) of the camshaft main gear at approx. 10 angle.
Approx. 10
A05525
Seal Packing Seal Width 1.5 mm
Groove
A05503
Remove any old packing (FIPG) material from the front bearing cap. (5) Apply seal packing to the front bearing cap as shown in the illustration. Seal packing: Part No. 08826-00080 or equivalent L Install a nozzle that is cut to a 1.5 mm (0.06 in.) opening. L Parts must be assembled within 5 minutes the seal packing application. Otherwise the material must be removed and the packing have to be reapplied. L Immediately remove nozzle from the tube and reinstall cap. NOTICE: Do not apply seal packing to the front bearing cap grooves.
(4)
Author :
Date :
1636
EM-64
(6)
Install the front bearing cap.
Front
A05504
HINT: Installing the front bearing cap will determine the thrust portion of the camshaft. (7) Install the other bearing cap in the sequence shown with the arrow mark facing forward. HINT: Align the arrow marks at the front and rear of the cylinder head with the mark on the bearing cap. (8) Push in the camshaft oil seal.
Push
A05505
(9)
A
Apply a light coat of engine oil on the threads and under the heads (D and E) of the bearing cap bolts.
HINT: Do not apply engine oil under the heads of the bearing cap bolt (A), (B) and (C).
E C
A04469
(10) Install the oil feed pipe and the 22 bearing cap bolts as shown. HINT: Bolt length: 94 mm (3.70 in.) for A 72 mm (2.83 in.) for B 25 mm (0.98 in.) for C 52 mm (2.05 in.) for D 38 mm (1.50 in.) for E (11) Evenly tighten the 22 bearing cap bolts a little at a time for several times as in the sequence shown. Torque: Bolt C: 7.5 Nm (80 kgfcm, 69 in.lbf) Others 16 Nm (160 kgfcm, 12 ftlbf)
10 7
5 6
18 17
21
2 1 3 4
15
16
13
14 11
12
19 20
22
A04469
Author :
Date :
1637
EM-65
(12) Move a service bolt of the sub-gear upward by turning the hexagon shaped port of the exhaust camshaft with a wrench. (13) Remove the service bolt.
Service Bolt
A04467
(c)
Install the LH camshafts. (1) Apply MP grease to the thrust portion of the intake and exhaust camshafts. (2) Place the intake and exhaust camshafts. (3) Engage the intake to the exhaust gear by putting the timing marks (2 dot marks) on each gear.
A05768
Seal Packing
Seal Width 1.5 mm
Groove
A05526
(4) Remove any old packing (FIPG) material. (5) Apply seal packing to the front bearing cap. Seal packing: Part No. 08826-00080 or equivalent L Install a nozzle that is cut to a 1.5 mm (0.06 in.) opening. L Parts must be assembled within 5 minutes the seal packing application. Otherwise the material must be removed and the packing have to be reapplied. L Immediately remove nozzle from the tube and reinstall cap. NOTICE: Do not apply seal packing to the front bearing cap grooves.
(6)
Install the front bearing cap.
Front
A05506
HINT: Installing the front bearing cap will determine the thrust portion of the camshaft. (7) Install the other bearing cap in the sequence shown with the arrow mark facing forward. HINT: Align the arrow marks at the front and rear of the cylinder head with the mark on the bearing cap.
EM-66
(8)
Push
Push in the camshaft oil seal.
A05507
(9)
Apply a light coat of engine oil on the threads and under the heads (D and E) of the bearing cap bolts.
B D
E
A04470
HINT: Do not apply engine oil under the heads of the bearing cap bolt (A), (B) and (C). (10) Install the oil feed pipe and the 22 bearing cap bolts as shown. HINT: Bolt length: 94 mm (3.70 in.) for A 72 mm (2.83 in.) for B 25 mm (0.98 in.) for C 52 mm (2.05 in.) for D 38 mm (1.50 in.) for E
21 18 17 6 5 1 2 3 4 22
7 10
(11) Uniformly tighten the 22 bearing cap bolts in several passes, in the sequence shown. Torque: Bolt C: 7.5 Nm (80 kgfcm, 69 in.lbf) Others 16 Nm (160 kgfcm, 12 ftlbf)
20 19 12 11 14
13
15 16
A04470
Service Bolt
A02856
(12) Move a service bolt of the sub-gear upward by turning the hexagon shaped port of the exhaust camshaft with a wrench. (13) Remove the service bolt. 9. CHECK AND ADJUST VALVE CLEARANCE (See page EM-4 ) Turn the camshaft and the position the cam lobe upward, and check and adjust the valve clearance.
Author :
Date :
1639
EM-67
Seal Packing
10. (a) (b)
INSTALL SEMI-CIRCULAR PLUGS Remove any old packing (FIPG) material. Apply seal packing to the semi-circular plug grooves. Seal packing: Part No. 08826-00080 or equivalent
EM7143
RH Cylinder Head
(c)
Install the 4 semi-circular plugs to the cylinder heads.
LH Cylinder Head
A07250
RH Cylinder Head Apply Seal Packing
11. (a) (b)
(c) (d) (e)

LH Cylinder Head
12. 13.
INSTALL CYLINDER HEAD COVER Remove any old packing (FIPG) material. Apply seal packing to the cylinder heads as shown in the illustration. Seal packing: Part No. 08826-00080 or equivalent Install the gasket to the cylinder head cover. Install the seal washer to the bolt. Install the cylinder head cover with the 18 bolts. Evenly tighten the bolts a little at a time for several times. Install the 2 cylinder head covers. Torque: 6.0 Nm (60 kgfcm, 53 in.lbf) INSTALL ENGINE HANGERS Torque: 37 Nm (380 kgfcm, 27 ftlbf) INSTALL OIL DIPSTICK AND GUIDE FOR ENGINE
Apply Seal Packing

A05509
Author :
Date :
1640
EM-68
14. (a) (b)
INSTALL REAR WATER BYPASS JOINT Install 2 new gaskets to the cylinder head. Install the 4 nuts holding the water bypass joint to the cylinder heads. Alternately tighten the nuts. Torque: 18 Nm (185 kgfcm, 13 ftlbf)
A05517
15. INSTALL FRONT WATER BYPASS JOINT Install 2 new gaskets and the water bypass joint with the 4 nuts. Alternately tighten the nuts. Torque: 18 Nm (185 kgfcm, 13 ftlbf) 16. INSTALL WATER INLET AND INLET HOUSING ASSEMBLY (See page CO-8 )
A05516
17.
A08655
White Painted Mark
ASSEMBLE UPPER AND LOWER INTAKE MANIFOLDS (a) Install the 2 delivery pipes and the 8 injectors (See page SF-27 ). (b) Install new 2 gaskets, the fuel pressure regulator and the fuel pulsation damper. (c) Install the fuel return hose to the lower intake manifold with the 3 bolts. (d) Connect the fuel return hose to the fuel pressure regulator. 18. INSTALL INTAKE MANIFOLD ASSEMBLY (a) Place 2 new gaskets on the cylinder heads with white painted mark facing upward. NOTICE: L Align the port holes of the gasket and cylinder head. L Be careful of the installation direction.
A03190
(b) (c)
Place the intake manifold assembly on the cylinder heads. Install and uniformly tighten the 6 bolts and the 4 nuts in several passes. Torque: 18 Nm (185 kgfcm, 13 ftlbf)
A17671
A19482
Author :
Date :
1641
EM-69
(d)
Install the EVAP pipe to the intake manifold with the 2 bolts.
A05514
(e) (f) (g) (h)
Connect the wire protector to the intake manifold with the 2 bolts. Install the engine wire to the engine hanger. Install the engine wire to the LH No.1 timing belt rear plate. Install the engine wire to the bracket.
A19472
(i) (j) (k)
Connect the wire protector to the rear water bypass joint and RH cylinder head with the 2 bolts. Install the 2 ground cables to the RH and LH cylinder head. Install the guide for A/T bracket to the LH cylinder head.
A05562
(l)
Connect the 2 wire clamps to the wire clamp bracket on the RH delivery pipe.
B01208
(q) (m) (r)
(m) (n)
(p)
(o) (p)
A19481
(o) (n)
A17668
(q)
Connect the fuel pressure regulator vacuum hose to the fuel pressure regulator pipe. Connect the PCV hose to the PCV valve on the LH cylinder head. Connect the EVAP hose (from charcoal canister) to the VSV for EVAP. Connect the EVAP hose (from charcoal canister) to the EVAP pipe on the intake manifold. Connect the EVAP hose (from intake air connector) to EVAP pipe on the the intake manifold.
EM-70
(r)
Connect the PS air hose to intake manifold.
B15320
No. 1 Water Bypass Hose
B16469
Connect the No.1 water bypass hose (from water inlet housing) to throttle body. (t) Connect the throttle control connector. (u) Connect the VSV connector for EVAP. (v) Connect the 8 injector connectors. (w) Connect the ECT sensor. (x) Connect the water sender gauge. (y) Connect the 8 ignition coil connectors. (z) Connect the 2 oxygen sensor connectors. 19. CONNECT FUEL INLET HOSE (See page SF-24 ) 20. INSTALL TIMING BELT REAR PLATES (a) Install the RH timing belt rear plates. Install the No.1 timing belt rear plate to the cylinder head with the 3 bolts and the stud bolt. Torque: 7.5 Nm (80 kgfcm, 66 in.lbf) (b) Install the LH timing belt rear plates. (1) Connect the wire clamp to the No.1 timing belt rear plate. (2) Install the No.1 timing belt rear plate to the cylinder head with the 3 bolts. Torque: 7.5 Nm (80 kgfcm, 66 in.lbf) 21. INSTALL V-BANK COVER Install the 3 V-bank covers. Torque: 7.5 Nm (80 kgfcm, 66 in.lbf) 22. INSTALL IGNITION COILS (See page IG-6 ) 23. INSTALL OIL DIPSTICK AND GUIDE FOR A/T 24. INSTALL FRONT EXHAUST PIPE (See page EM-1 15) 25. INSTALL PS PUMP (See page EM-81 ) 26. INSTALL CAMSHAFT POSITION SENSOR (See page IG-10 ) 27. INSTALL CAMSHAFT TIMING PULLEYS (See page EM-22 ) 28. CONNECT TIMING BELT TO CAMSHAFT TIMING PULLEYS (See page EM-22 ) 29. CHECK ENGINE OIL LEVEL
(s)
Author :
Date :
1643
EM-57
EM0L4-08
REASSEMBLY
HINT:
L L L
Thoroughly clean all parts to be assembled. Before installing the parts, apply new engine oil to all sliding and rotating surfaces. Replace all gaskets and oil seals with new ones.
Adhesive
1. INSTALL SPARK PLUG TUBES HINT: When using a new cylinder head, the spark plug tubes must be installed. (a) Apply adhesive to the end of the spark plug tube. Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent
P08885
15 mm (0.59 in.)
(b)
Protrusion
Using a wooden block and hammer, tap in a new spark tube until the protrusion from the camshaft bearing cap installation surface of the cylinder head becomes 48.4 49.6 mm (1.906 - 1.953 in.). NOTICE: Avoid tapping a new spark plug tube in too far by measuring the amount of the protrusion as tapping.
A03212
SST
2. (a)
INSTALL VALVES Using SST, push in a new oil seal. SST 09201-41020
A05710
(4) (3) (2) (1)
(b)
Install the valve (1), the spring seat (2), the valve spring (3),and the spring retainer (4).
A05711
Author :
Date :
1630
EM-58
SST
(c)
Using SST, compress the valve spring and place the 2 keepers around the valve stem. SST 09202-70020
A05712
(d)
Using a plastic-faced hammer and the valve stem tip taped up with vinyl tape, lightly tap the valve stem tip to assure proper fit. NOTICE: Be careful not to damage the valve stem tip. 3. INSTALL SHIMS AND VALVE LIFTERS (a) Install the shim and the valve lifter. (b) Check that the valve lifter rotates smoothly by hand.
A07306
Author :
Date :
1631
EM-35
EM1V8-01
REMOVAL
1. DRAIN ENGINE COOLANT 2. REMOVE V-BANK COVER Remove the V-bank covers. 3. DISCONNECT TIMING BELT FROM CAMSHAFT TIMING PULLEYS (See page EM-15 ) 4. REMOVE CAMSHAFT TIMING PULLEYS (See page EM-15 ) 5. REMOVE CAMSHAFT POSITION SENSOR (See page IG-9 ) 6. DISCONNECT PS PUMP FROM ENGINE (See page EM-77 ) 7. REMOVE FRONT EXHAUST PIPE (See page EM-1 15) 8. REMOVE OIL DIPSTICK AND GUIDE FOR A/T 9. REMOVE IGNITION COILS (See page IG-6 ) 10. REMOVE TIMING BELT REAR PLATES (1) Remove the 3 bolts, the stud bolt, and the RH No.1 timing belt rear plates. (2) Disconnect the wire clamp from the LH timing belt rear plate. (3) Remove the 3 bolts, the stud bolt, the LH No.1 and the timing belt rear plates.
A02844
NOTICE: L Be careful not to drop anything inside the timing belt cover. L Do not allow the belt to contact correct with oil, water or dust. 11. DISCONNECT FUEL INLET HOSE (See page SF-24 ) 12. REMOVE INTAKE MANIFOLD ASSEMBLY (a) Disconnect the throttle control connector. (b) Disconnect the VSV connector for EVAP. (c) Disconnect the 8 injector connectors. (d) Disconnect the ECT sensor connector. (e) Disconnect the water sender gauge connector. (f) Disconnect the 8 ignition coil connectors. (g) Disconnect the 2 oxygen sensor connectors.
Author :
Date :
1608
EM-36
(l) (n) (m)
(h) (i)
(k)
(j) (k)
(i)
A17668
(j)
A19481
(l) (m)
Disconnect the fuel pressure regulator vacuum hose from the fuel pressure regulator pipe. Disconnect the PCV hose from the PCV valve on the LH cylinder head. Disconnect the EVAP hose (from charcoal canister) from VSV for EVAP. Disconnect the EVAP hose (from charcoal canister) from the EVAP pipe on the intake manifold. Disconnect the EVAP hose (from intake air connector) from the EVAP pipe on the intake manifold. Disconnect the PS air hose from the intake manifold.
(n)
Disconnect the No.1 water bypass hose from the front water by-pass joint.
B15320
No. 1 Water Bypass Hose
B16469
(o)
Disconnect the 2 wire clamps from the wire clamp bracket on the RH delivery pipe.
Wire Clamp
A17670
(p)
(q)
Wire Protector
(r)
Remove the 2 bolts and disconnect the engine wire protector from the rear water bypass joint and the RH cylinder head. Remove the guide for A/T bracket from the LH cylinder head. Remove the 2 ground cables from the RH and LH cylinder head.
Ground Cable
A08664
Author :
Date :
1609
EM-37
(s) (t) (u) (v)
Remove the 2 bolts and disconnect the engine wire protector from the intake manifold. Remove the engine wire from the engine hanger. Remove the engine wire from the wire bracket. Remove the RH rear and the LH front V-bank cover brackets.
A19472
(w)
Remove the 6 bolts, the 4 nuts, the intake manifold assembly and the 2 gaskets.
A17671
A19482
13. (a) (b) (c)
A17679
(d) (e)
DISASSEMBLE UPPER AND LOWER INTAKE MANIFOLDS Remove the throttle body (See page SF-36 ). Remove the 13 bolts, the 3 nuts, the upper intake manifold and the gasket. Disconnect the EVAP hose from the upper intake manifold, and remove the accelerator cable clamp and VSV for EVAP. Remove the bolt, the union, the 2 gaskets and the brake booster tube from the upper intake manifold. Remove the 2 bolts and the EVAP pipe from the intake manifold.
EVAP Pipe
A09148
(f) (g) (h) (i) (j)

A08655
Disconnect the fuel return hose from the fuel pressure regulator. Remove the 3 bolts holding the fuel return hose from the lower intake manifold. Remove the fuel pressure regulator, the fuel pressure pulsation damper and the 2 gaskets. Remove the bolt and the rear fuel pipe. Remove the 2 delivery pipes and the 8 injectors (See page SF-22 ).
EM-38
14.
REMOVE WATER INLET AND INLET HOUSING ASSEMBLY (See page CO-6 )
15. REMOVE FRONT WATER BYPASS JOINT Remove the 4 nuts, the water bypass joint and the 2 gaskets.
A05516
16. REMOVE REAR WATER BYPASS JOINT Remove the 4 nuts, the water bypass joint and the 2 gaskets. 17. REMOVE ENGINE HANGERS 18. REMOVE OIL DIPSTICK AND GUIDE FOR A/T
A05517
A05564
19. REMOVE CYLINDER HEAD COVERS Remove the 18 bolts, the 18 seal washers, the cylinder head cover and gasket. Remove the 2 cylinder head covers. 20. IF NECESSARY, REMOVE SEMI-CIRCULAR PLUGS AND CAMSHAFT HOUSING PLUGS 21. REMOVE CAMSHAFTS NOTICE: Since the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being removed. Otherwise, excessive pressure is put on the cylinder head journal thrust, causing a burr on the journal and damage on the camshaft. To avoid this, follow the steps below.
Author :
Date :
1611
EM-39
(a)
No. 2 Idler Pulley Bolt
Timing Mark Crankshaft Pulley Bolt

A04456
Check the crankshaft pulley position. Check that the timing mark of the crankshaft pulley is aligned with the centers of the crankshaft pulley bolt and the idler pulley bolt. NOTICE: Having the crankshaft pulley at the wrong angle can cause the piston head and the valve head to come into contact with each other when removing the camshaft, causing damage on them. So always set the crankshaft pulley at the correct angle. (b) Remove the RH camshafts. (1) Move a service bolt of the sub-gear upward by turning the hexagon shaped port of the exhaust camshaft with a wrench. (2) Secure the sub-gear to the main gear with a service bolt. Recommended service bolt:
Thread diameter 6 mm 1.0 mm 16 - 20 mm Thread pitch Bolt length
Service Bolt
A04467
HINT: When removing the camshafts, make sure that the torsional spring force of the sub-gear is eliminated by the above operation. (3) Set the timing mark (1 dot mark) of the camshaft main gear at approx. 10 angle by turning the hexagon wrench head portion of the exhaust camshaft with a wrench.
A04468
13 14 16
15 18
17 6
(4)
2 21 22
(5)
20 8 7 10 9 12 11 4 3 19 1
A04469
Uniformly loosen and remove the 22 bearing cap bolts a little at a time for several times in the sequence shown. Remove the oil feed pipe, 9 bearing caps, cam shaft timing oil control valve and camshafts.
Author :
Date :
1612
EM-40
(c)
Remove the LH camshafts. (1) Move a service bolt of the sub-gear upward by turning the hexagon shaped port of the exhaust camshaft with a wrench. (2) Secure the sub-gear to the main gear with a service bolt. Recommended service bolt:
Thread diameter 6 mm 1.0 mm 16 - 20 mm Thread pitch Bolt length
Service Bolt
A02856
Align
HINT: When removing the camshaft, make sure that the torsional spring force of the sub-gear is eliminated by the above operation. (3) Align the timing mark (2 dot marks) of the camshaft drive gear by turning the hexagon wrench head portion of the exhaust camshaft with a wrench.
A02857
2 21
5 6
17 18
15 16
13 14
(4)
(5)
22 20 19 1 4 3 11 12 9 10 7 8
A04470
Evenly loosen and remove the 22 bearing cap bolts a little at a time for several times as in the sequence shown. Remove the oil feed pipe, 9 bearing caps, and camshafts.
HINT: Arrange the bearing caps in correct order for installation.
22. (a)
DISASSEMBLE EXHAUST CAMSHAFTS Mount the hexagon wrench head portion of the camshaft in a vise. NOTICE: Be careful not to damage the camshaft.
A02859
Service Bolt
(b)
Using SST, turn the sub-gear clockwise, and remove the service bolt. SST 09960-10010 (09962-01000, 09963-00500)
Turn SST
A02850
Author :
Date :
1613
EM-41
A02861
(c) Using snap ring pliers, remove the snap ring. (d) Remove the wave washer. (e) Remove the camshaft sub-gear. (f) Remove the camshaft gear spring. HINT: Arrange the camshaft sub-gears and gear spring (RH and LH sides). NOTICE: Be careful not to damage the camshaft timing tube. 23. 24. REMOVE OIL SEAL FROM INTAKE CAMSHAFT REMOVE SPARK PLUGS
Oil Seal
A04471
25.
RH Cylinder Head
1 7 9 6 4
REMOVE CYLINDER HEAD AND EXHAUST MANIFOLD ASSEMBLIES (a) Uniformly loosen the 10 cylinder head bolts on one side of each cylinder head in a little at a time for several times as in the sequence shown, then do the other side as shown. Remove the 20 cylinder head bolts and the plate washers. NOTICE: L Removing the bolts in incorrect order could cause a warp or cracks in the cylinder head.
3 2
5 8
10
8 5
2 3
LH Cylinder Head
Front
10
1
A04472
Author :
Date :
1614
EM-42
RH Cylinder Head A
Do not drop the plate washer of the cylinder head bolt into A area in the illustration. It will fall down to the oil pan through the cylinder head and the cylinder block.
LH Cylinder Head A
A04473
(b)
Lift the cylinder head from the dowels on the cylinder block, and place the 2 cylinder heads on wooden blocks.
A02871
HINT: After lifting off the cylinder head, pry off the cylinder head and the cylinder block with a screwdriver. NOTICE: L Be careful not to damage the contact surfaces of the cylinder head and the cylinder block. L The cylinder head should not be tilted so to secure the valve lifter. If the cylinder head is tilted, remove the valve lifter and check that the adjusting shim is set correctly.
26. (a) (b)
REMOVE RH EXHAUST MANIFOLD FROM CYLINDER HEAD Remove the 4 bolts and the heat insulator. Remove the 8 nuts, the exhaust manifold and the gasket.
A05498
Author :
Date :
1615
EM-43
27. (a) (b)
REMOVE LH EXHAUST MANIFOLD FROM CYLINDER HEAD Remove the 4 bolts and the heat insulator. Remove the 8 nuts, the exhaust manifold and the gasket.
A05518
Author :
Date :
1616
EM-55
EM0L3-07
80-100 C
REPLACEMENT
1. (a) REPLACE VALVE GUIDE BUSHINGS Gradually heat the cylinder head to 80 - 100C (176 212F).
A03195
(b)
Using SST and a hammer, tap out the guide bushing. SST 09201-10000 (09201-01060), 09950-70010 (09951-07100)
SST
A05708
(c)
Using a caliper gauge, measure the bushing bore diameter of the cylinder head.
A03197
Both intake and exhaust Bushing bore diameter mm (in.) 10.285 - 10.306 (0.4049 - 0.4057) 10.335 - 10.356 (0.4069 - 0.4077) Bushing size Use STD Use O/S STD
(d) Select a new guide bushing (STD or O/S 0.05). If the bushing bore diameter of the cylinder head is greater than 10.306 mm (0.4057 in.), machine the bushing bore to the following dimension: 10.335 - 10.356 mm (0.4069 - 0.4077 in.) If the bushing bore diameter of the cylinder head is greater than 10.356 mm (0.4077 in.), replace the cylinder head.
Intake
Exhaust
HINT: The intake bushing and the exhaust bushing differ in their sizes.
34.5 mm (1.358 in.)
40.5 mm (1.594 in.)
P21844
Author :
Date :
1628
EM-56
(e)
SST
(f)
A05709
Sharp 5.5 mm Reamer
(g)
Gradually heat the cylinder head to 80 - 100C (176 212F). Using SST and a hammer, tap in a new guide bushing to the specified protrusion height. Protrusion height: Intake 9.2 - 9.8 mm (0.362 - 0.386 in.) Exhaust 8.2 - 8.8 mm (0.323 - 0.346 in.) SST 09201-10000 (09201-01060), 09950-70010 (09951-07100) Using a sharp 5.5 mm reamer, ream the guide bushing to obtain the standard specified clearance (See page EM-45 ) between the guide bushing and the valve stem.
A03199
A03200
Bend Claw
Pry
REPLACE SPARK PLUG TUBE GASKETS Bend the 4 ventilation case claws installed on the cylinder head cover to an angle of 90 or more. (b) Using a screwdriver, pry out the gasket. NOTICE: Be careful not to damage the cylinder head cover. Tape up the screwdriver tip.
A04107
2. (a)
SST
(c)
Return SST Claw Downward

A04108
Using SST and a hammer, tap in a new gasket until its surface is flush with the upper edge of the cylinder head cover. SST 09950-60010 (09551-00240, 09951-00440, 09952-06010) 09950-70010 (09951-07100) NOTICE: Be careful of the installation direction. (d) Apply a light coat of MP grease to the gasket lip. (e) Put the 4 ventilation case claws back to its original position.
Author :
Date :
1629
EM-71
ENGINE MECHANICAL ENGINE UNIT
ENGINE UNIT
EM0LB-09
COMPONENTS
Fuel Return Hose Hood
V-Bank Cover MAF Meter Connector
PS Air Hose Air Inlet Hose for EVAP
Air Cleaner Cap and Intake Air Connector Assembly
Vacuum Sensing Hose
Windshield Washer Hose
PCV Hose Battery Hold-Down Clamp
Battery Positive (+) Terminal Cable
Battery Negative (-) Terminal Cable Battery Battery Tray
Engine Under Cover Engine Under Cover
A19473
Author :
Date :
1644
EM-72
A/C Discharge Tube Charge Valve Clamp Clamp Radiator Reservoir Hose
Clamp Wire Upper Radiator Hose
Radiator Reservoir
Bracket
Bracket
Grommet
Support Collar
Fan Shroud
A/T Oil Cooler Hose Radiator Lower Radiator Hose
Fan w/ Fluid Coupling Assembly
Fan Pulley
A07248
Author :
Date :
1645
EM-73
Wire Harness Connector ECM Connector Grove Compartment Door A/B Connector A/B Connector Cover
ECM
Lower No.2 Panel
A07249
Engine Wire Clamp Engine Wire Grommet
Heater Hose
Ground Strap Connector Heater Hose Fuel Return Hose
Generator Wire
PS Air Hose
Generator Connector Fuel Inlet Hose Hose Clamp Clamp Engine Wire Clamp
Clamp
PS Air Hose
Batter Positive (+) Terminal Cable
Battery Negative (-) Cable

A19474
Author :
Date :
1646
EM-74
Transfer Shift Lever Knob Connector Upper Console Panel
Connector
Connector
Shift Lever Assembly
x6
Transfer Shift Lever Boot
8.3 (86, 73) in.lbf
Transfer Shift Lever Assembly
Bushing
z Gasket
Wave Washer
Transfer Shift Lever Rod
Plate Washer
Transmission Control Rod Clip Nm (kgfcm, ftlbf) : Specified torque z Non-reusable part
2004 LAND CRUISER (RM1071U) 13 (130, 9)
A19475
Author :
Date :
1647
EM-75
106 (1,080, 78)
PS Pump
62 (632, 46)
Rear Propeller Shaft Front Propeller Shaft
80 (820, 59)
Heated Oxygen Sensor (Bank 1 Sensor 2) Connector
Engine and Transmission Assembly Transfer Case Protector
30 (310, 22) 74 (750, 55)
A/C Compressor Connector A/C Compressor
Heated Oxygen Sensor (Bank 2 Sensor 2) Connector z Gasket
z Gasket
50 (510, 37)
z z z z Gasket z Front Exhaust Pipe z z z Stabilizer Bar z Nm (kgfcm, ftlbf) : Specified torque z Non-reusable part
2004 LAND CRUISER (RM1071U) 40 (408, 30)
z Gasket
Bracket z
Front Exhaust Pipe

62 (632, 46)
Bracket
A19476
Author :
Date :
1648
EM-76
Stay
Stay Stay Clamp
Connector Connector Oil Cooler Pipe for Transmission
Transmission (w/ Torque Converter Clutch)
x 10
37 (380, 27) for 14 mm Head 72 (730, 53) for 17 mm Head
L Engine
See page EM-81 1st 49 (500, 36) 2nd Turn 90
Rear Spacer Front Spacer x8
Drive Plate x6
48 (490, 35)
Flywheel Housing Under Cover
Nm (kgfcm, ftlbf) : Specified torque z Non-reusable part L Precoated part

A21821
Author :
Date :
1649
EM-81
EM0LA-07
INSTALLATION
1. INSTALL DRIVE PLATE HINT: L The mounting bolts are tightened in 2 steps (steps (c) and (e)). L If any one of the mounting bolts is broken or deformed, replace it.
(a)
Adhesive
Apply adhesive to 2 or 3 threads of the mounting bolt end. Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent
A04869
(b)
1 8 3 4 7 6 2
A04857
Install the front spacer, the drive plate and the rear spacer on the crankshaft. (c) Hold the crankshaft pulley bolt with a wrench, and install and evenly tighten the 8 mounting bolts, a little at a time for several times as in the sequence shown. Torque: 49 Nm (500 kgfcm, 36 ftlbf) If any one of the mounting bolts does not meet the torque specification, replace the mounting bolt.
(d) (e)
Painted Mark 90 90
A05137
(f)
Mark the mounting bolt with paint. Retighten the mounting bolts by 90 in the numerical order shown. Check that the painted mark is now at a 90 angle to (e).
2. (a) (b) (c)
Ground Strap
INSTALL TRANSMISSION TO ENGINE Check the torque converter clutch installation. (See page AT-33 ) Attach the transmission to the engine. Install the ground strap and 10 bolts. Torque: 37 Nm (380 kgfcm, 27 ftlbf) for 14 mm head 72 Nm (730 kgfcm, 53 ftlbf) for 17 mm head
A05119
Author :
Date :
1654
EM-82
Adhesive
3. (a)
INSTALL TORQUE CONVERTER CLUTCH BOLTS Apply adhesive to 2 or 3 threads from the bolt end. Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent
P18747
(b)
Hold the crankshaft pulley bolt with a wrench, and install the 6 bolts evenly. Torque: 48 Nm (490 kgfcm, 35 ftlbf)
HINT: First install the black colored bolt, install the other bolts.
A05084
(c) 4. 5. (a) (b)
Install the flywheel housing under cover with the bolt. Torque: 18 Nm (185 kgfcm, 13 ftlbf) INSTALL OIL COOLER PIPE FOR TRANSMISSION CONNECT ENGINE WIRE TO TRANSMISSION Connect the 5 connectors. Connect the 2 wire clamps.
A07245
Lower
6. (a) (b) (c)
Up
INSTALL ENGINE AND TRANSMISSION ASSEMBLY IN VEHICLE Attach the engine chain hoist to the engine hangers. Slowly lower the engine and the transmission assembly into the engine compartment. Attach the engine mounting brackets to the frame brackets.
A05171
(d)
Keep the engine level with a jack.
A05170
Author :
Date :
1655
EM-83
(e)
(f)
Install the frame crossmember with the 8 bolts and the 4 nuts. Torque: 50 Nm (510 kgfcm, 37 ftlbf) for bolts 74 Nm (750 kgfcm, 55 ftlbf) for nuts Install the transfer case protector with the 3 bolts.
A05125
(g)
Install the 2 nuts and the 4 bolts holding the engine mounting brackets to the frame brackets. Torque: 30 Nm (310 kgfcm, 22 ftlbf) (h) Remove the engine chain hoist. 7. INSTALL PS PUMP Install the PS pump with the 3 bolts. Torque: 62 Nm (632 kgfcm, 46 ftlbf)
A05126
8. (a) (b) 9. 10. 11.

A05127
INSTALL A/C COMPRESSOR Install the A/C compressor with the 3 bolts. Torque: 49 Nm (500 kgfcm, 36 ftlbf) Connect the A/C compressor connector. INSTALL STABILIZER BAR (See page SA-82 ) INSTALL PROPELLER SHAFT (See page PR-7 ) INSTALL FRONT EXHAUST PIPES
12. (a)
A07247
(b) (c)
INSTALL SHIFT LEVER ASSEMBLY AND TRANSFER SHIFT LEVER ASSEMBLY Install the transfer shift lever. (1) Install a new gasket and the shift lever with the 4 bolts. (2) Connect the transfer shift lever rod to the shift lever with the bushing, the wave washer, the plate washer and the clip. Install the transfer shift lever boot with the 4 bolts. Install the shift lever assembly. (1) Connect the transmission control rod to the shift lever assembly with the nut. Torque: 13 Nm (130 kgfcm, 9 ftlbf) (2) Install the shift lever assembly with the 6 bolts. Torque: 8.3 Nm (86 kgfcm, 73 in.lbf) (3) Connect the connector. Install the console upper cover. Install the transfer shift lever knob.
A19477
(d) (e)
Author :
Date :
1656
EM-84
13. (a) (b) (c) (d) (e) (f) (g) (h) (i) (j) (k) (l) (m) (n) (o) (p) (q) 14. (a) (b) (c) (d) (e) 15. (a) (b) (c) 16. (a) (b) (c) (d) (e) (f) (g)
CONNECT HOSES, WIRES, CONNECTORS, CLAMPS, GROMMET AND CABLES Connect the 2 PS air hoses to the hose clamp on the No.3 RH timing belt cover. Connect the generator wire. Connect the generator connector. Connect the hose clamp for the PS air hose. Connect the PS air hose to upper intake manifold. Connect the 2 heater hoses. Connect the engine wire clamp to the bracket on the cowl panel. Connect the engine wire grommet to the cowl panel. Connect the ground strap connector. Connect the fuel main hose and the clamps. Connect the fuel return hose and the clamp. Connect the air inlet hose to the charcoal canister. Connect the EVAP hose to the charcoal canister. Connect the engine wire to the clamp on the right fender apron. Connect the clamp on battery negative (-) cable to the relay box. Connect the battery negative (-) cable to the right fender apron. Connect the battery positive (+) terminal cable. CONNECT ENGINE WIRE TO CABIN Connect the 3 wire harness connectors. Install the ECM with the 3 screws. Connect the 3 connectors to the ECM. Install the glove compartment door. Install the lower No.2 panel. INSTALL FAN PULLEY, FAN, FLUID COUPLING AND GENERATOR DRIVE BELT Temporarily install the fan pulley, the fan and the fluid coupling assembly with the 4 nuts. Install the generator drive belt. (See page CH-16 ) Tighten the 4 nuts holding the fluid coupling to the fan bracket. INSTALL RADIATOR AND FAN SHROUD Place the fan shroud in the installation position. Install the radiator with the 2 support collars, the 2 nuts and the 2 bolts. Connect the 2 A/T oil cooler hoses to the radiator. Install the lower radiator hose. Attach the lower side of the fan shroud to the brackets of the radiator, and install the fan shroud with the 2 bolts. Install the 2 brackets on the wire to the radiator with the 2 bolts. Install the 2 clamps on the A/C discharge tube to the brackets on the wire with the 2 nuts.
Author :
Date :
1657
EM-85
(h)
Connect the upper radiator hose to the front water bypass joint. 17. INSTALL RADIATOR RESERVOIR (a) Install the grommet to the reservoir. (b) Attach the lower side of the reservoir to the fan shroud. (c) Install the reservoir with the 2 bolts. (d) Connect the reservoir hose to the radiator. (e) Install the clamp on the wire to the reservoir. 18. INSTALL AIR CLEANER CAP AND INTAKE AIR CONNECTOR PIPE ASSEMBLY 19. INSTALL BATTERY 20. FILL WITH ENGINE COOLANT (See page CO-2 ) 21. FILL WITH ENGINE OIL (See page LU-2 ) 22. START ENGINE AND CHECK FOR LEAKS 23. INSTALL V-BANK COVER 24. INSTALL ENGINE UNDER COVERS 25. INSTALL HOOD 26. PERFORM ROAD TEST Check for abnormal noise, shock, slippage, and make sure the shift points is correct and operation is smooth. 27. RECHECK ENGINE COOLANT AND OIL LEVELS
Author :
Date :
1658
EM-77
EM0L9-07
REMOVAL
1. 2. 3. 4. 5. 6. 7. 8. (a) (b) (c) 9. (a) (b) (c) (d) (e) (f) (g) (h) 10. (a) (b) (c) 11. (a) (b) (c) (d) (e) 12. (a) (b) (c) (d) (e)
REMOVE HOOD REMOVE ENGINE UNDER COVERS DRAIN ENGINE COOLANT DRAIN ENGINE OIL REMOVE V-BANK COVER REMOVE BATTERY REMOVE AIR CLEANER CAP AND INTAKE AIR CONNECTOR PIPE ASSEMBLY REMOVE RADIATOR RESERVOIR Disconnect the clamp on the wire from the reservoir. Disconnect the reservoir hose from the radiator. Remove the 2 bolts, the reservoir and the grommet. REMOVE RADIATOR AND FAN SHROUD Disconnect the upper radiator hose from the front water bypass joint. Remove the 2 nuts, and disconnect the 2 clamps on the A/C discharge tube from the bracket. Remove the 2 bolts, and disconnect the 2 brackets on the wire from the radiator. Remove the 3 bolts, and disconnect the fan shroud from the radiator. Remove the lower radiator hose. Disconnect the 2 A/T oil cooler hoses from the radiator. Remove the 2 bolts, the 2 nuts, the 2 support collars and the radiator. Remove the fan shroud. REMOVE GENERATOR DRIVE BELT, FAN, FLUID COUPLING AND FAN PULLEY Loosen the 4 nuts holding the fluid coupling to the fan bracket. Remove the generator drive belt. (See page CH-7 ) Remove the 4 nuts, the fan, the fluid coupling assembly and the fan pulley. DISCONNECT ENGINE WIRE FROM CABIN Remove the glove compartment door. Remove the lower No.2 panel. Disconnect the 3 connectors from the ECM. Remove the 3 screws, and disconnect ECM from the body bracket. Disconnect the 3 wire harness connectors. DISCONNECT HOSES, WIRES, CONNECTORS, CLAMPS, GROMMET AND CABLES Disconnect the 2 PS air hoses from the hose clamp on the No.3 RH timing belt cover. Disconnect the generator wire. Disconnect the generator connector. Disconnect the hose clamp for PS air hose. Disconnect the PS air hose from upper intake manifold.
Author :
Date :
1650
EM-78
(f) (g) (h) (i) (j) (k) (l) (m) (n) (o) (p) (q) 13. (a) (b) (c)
(d)
A19477
Disconnect the 2 heater hoses. Disconnect the engine wire clamp from the bracket on the cowl panel. Disconnect the engine wire grommet from cowl panel. Disconnect the ground strap connector. Disconnect the fuel main hose and the clamps. Disconnect the fuel return hose and the clamp. Disconnect the air inlet hose from the charcoal canister. Disconnect the EVAP hose from the charcoal canister. Disconnect the engine wire from the clamp on the right fender apron. Disconnect the clamp on battery negative (-) cable from the relay box. Disconnect the battery negative (-) cable from the right fender apron. Disconnect the battery positive (+) terminal cable. REMOVE SHIFT LEVER ASSEMBLY AND TRANSFER SHIFT LEVER ASSEMBLY Remove the transfer shift lever knob. Remove the upper console panel. Remove the shift lever assembly. (1) Disconnect the connector. (2) Remove the 6 bolts. (3) Remove the nut and disconnect the transmission control rod from the shift lever assembly. (4) Remove the shift lever assembly. Remove the 4 bolts and the transfer shift lever boot.
(e)
A07247
14. 15. 16. 17. (a) (b)
Remove the transfer shift lever assembly. (1) Remove the clip, the plate washer and the wave washer, and disconnect the transfer rod from the shift lever. (2) Remove the bushing. (3) Remove the 4 bolts, the shift lever and the gasket. REMOVE FRONT EXHAUST PIPES REMOVE PROPELLER SHAFT (See page PR-4 ) REMOVE STABILIZER BAR (See page SA-81 ) DISCONNECT A/C COMPRESSOR FROM ENGINE Disconnect the A/C compressor connector. Remove the 3 bolts, and disconnect the A/C compressor from the engine.
HINT: Suspend the A/C compressor securely.
A05127
Author :
Date :
1651
EM-79
18. DISCONNECT PS PUMP FROM ENGINE Remove the 3 bolts, and disconnect the PS pump from the engine. HINT: Suspend the PS pump securely.
19. (a) (b) (c)
REMOVE ENGINE AND TRANSMISSION ASSEMBLY FROM VEHICLE Attach the engine chain hoist to the engine hangers. Remove the 2 nuts and the 4 bolts holding the engine mounting brackets to the frame brackets. Remove the 3 bolts and the transfer case protector.
A05126
(d)
Remove the 8 bolts, the 2 nuts and the frame crossmember.
A05125
Lift Down
(e)
Lift the engine and take out from the vehicle slowly and carefully.
A05172
HINT: Make sure the engine is clear of all wiring, hoses and cables. (f) Place the engine and transmission assembly onto a stand. 20. DISCONNECT ENGINE WIRE FROM TRANSMISSION (a) Disconnect the 5 connectors. (b) Disconnect the 2 wire clamps. 21. REMOVE OIL COOLER PIPES FOR TRANSMISSION (a) Remove the 3 bolts and the 3 stays. (b) Loosen the 2 union nuts, and remove the 2 oil cooler pipes.
Author :
Date :
1652
EM-80
22. (a)
REMOVE TORQUE CONVERTER CLUTCH BOLTS Remove the bolt and the flywheel housing under cover.
A07245
(b) (c)
Turn the crankshaft pulley bolt to gain access to each bolt. Hold the crankshaft pulley bolt with a wrench, and remove the 6 bolts.
A05084
23. (a) (b)
REMOVE TRANSMISSION Remove the 10 bolts. Remove the transmission together with the torque converter clutch from the engine.
A05119
24. REMOVE DRIVE PLATE Hold the crankshaft pulley bolt with a wrench, and remove the 8 bolts, the front spacer, the drive plate and the rear spacer.
A04857
Author :
Date :
1653
EM-1 15
ENGINE MECHANICAL EXHAUST SYSTEM
EXHAUST SYSTEM
EM0EE-18
COMPONENTS
Ring Ring Heat Insulator z z Ring
85 (867, 63)
Ring Ring Tailpipe Heat Insulator
40 (408, 30)
z Clamp z z Center Exhaust Pipe Heat Insulator z z

20 (200, 14)
z Gasket
No.2 Front Exhaust Pipe
Heat Insulator
z z
Heated Oxygen Sensor (Bank 2 Sensor 2) z Gasket Heated Oxygen Sensor (Bank 1 Sensor 2) z
z Gasket
z Gasket Front Exhaust Pipe
z Ring
z Gasket z z TWC z Gasket z Gasket z z
40 (408, 30)
Front Exhaust Pipe z z
TWC z
62 (632, 46)
Heat Insulator
Nm (kgfcm, ftlbf) : Specified torque z Non-reusable part
A19478
Author :
Date :
1688
EM-1 1
ENGINE MECHANICAL IDLE SPEED
IDLE SPEED
EM0KU-10
INSPECTION
1. INITIAL CONDITIONS (a) Engine is at normal operating temperature (b) Air cleaner is installed (c) All pipes and hoses of air induction systems are connected (d) All accessories are switched OFF (e) All vacuum lines are properly connected HINT: All vacuum hoses should be properly connected. (f) SFI system wiring connectors are fully plugged (g) Ignition timing is set correctly (h) Transmission is in neutral position (i) Air conditioning switches are OFF 2. CONNECT TOYOTA HAND-HELD TESTER OR OBD II SCAN TOOL (See page EM-9 ) 3. INSPECT IDLE SPEED (a) Race the engine speed at 2,500 rpm for approx. 90 seconds. (b) Check the idle speed. Idle speed: 700 50 rpm If the idle speed is not as specified, check the air intake system. 4. DISCONNECT TOYOTA HAND-HELD TESTER OR OBD II SCAN TOOL
Author :
Date :
1584
EM-9
ENGINE MECHANICAL IGNITION TIMING
IGNITION TIMING
EM0KT-10
INSPECTION
1. REMOVE BATTERY CLAMP COVER 2. REMOVE INTAKE AIR CONNECTOR 3. REMOVE V-BANK COVER 4. WARM UP ENGINE Allow the engine to warm up to the normal operating temperature.
TOYOTA Hand-Held Tester
5. (a) (b)
CONNECT TOYOTA HAND-HELD TESTER OR OBD II SCAN TOOL 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 operators manual for further details.
DLC3
A07061
A05511
6. CONNECT TIMING LIGHT TO ENGINE Connect the tester probe of a timing light to the wire of the ignition coil connector for No.1 cylinder. 7. CHECK IDLE SPEED (a) Race the engine speed at 2,500 rpm for approx. 90 seconds. (b) Check the idle speed. Idle speed: 700 50 rpm 8. (a) INSPECT IGNITION TIMING Using SST, connect terminal TC and E1 of the DLC1. SST 09843-18020
TC
SST
E1
A05512
(b)
(c) 9. 10.
A04459
Using a timing light, check the ignition timing. Ignition timing: 5 - 15 BTDC @ idle (Transmission in neutral position) Remove SST from the DLC1. SST 09843-18020 DISCONNECT TIMING LIGHT FROM ENGINE DISCONNECT TOYOTA HAND-HELD TESTER OR OBD II SCAN TOOL
Author :
Date :
1582
EM-10
ENGINE MECHANICAL IGNITION TIMING
11. 12. 13.
REINSTALL V-BANK COVER REINSTALL INTAKE AIR CONNECTOR REINSTALL BATTERY CLAMP COVER
Author :
Date :
1583
EM-12
ENGINE MECHANICAL TIMING BELT
TIMING BELT
EM0KV-1 1
COMPONENTS
V-Bank Cover A/C Discharge Tube Clamp Clamp Fuel Return Hose
Wire Clamp Bracket P/S Air Hose EVAP Hose Intake Air Connector Air Hose Bracket Radiator Reservoir Tank
5.0 (50, 43 in.lbf)
Fan Shroud
Lower Radiator Hose

18 (185, 13)
A/T Oil Cooler Hose
Radiator Assembly
Fan Pulley
Fan w/ Fluid Coupling

20 (200, 15)
A/C Compressor Connector A/C Compressor A/T Oil Cooler Hose

49 (500, 36)
x8 Nm (kgfcm, ftlbf) : Specified torque
Engine Under Cover No.1
A09750
Author :
Date :
1585
EM-13
RH No. 3 Timing Belt Cover
7.5 (80, 66 in.lbf)
No. 2 Timing Belt Cover

16 (160, 12)
Drive Belt Idler Pulley

39 (400, 29)
Cover Plate Camshaft Position Sensor Connector
Wire Grommet Engine Wire

7.5 (80, 16 in.lbf)
LH No. 3 Timing Belt Cover
Oil Cooler Pipe Nm (kgfcm, ftlbf) : Specified torque

A04326
RH Camshaft Timing Pulley LH Camshaft Timing Belt Pulley Timing Belt
108 (1,100, 80)
245 (2,500, 181)
16 (160, 12) 32 (330, 24)
Dust Boot Fan Bracket

26 (270, 19)
Timing belt Tensioner
Nm (kgfcm, ftlbf) : Specified torque

A04327
Author :
Date :
1586
EM-14
Generator Wire
Drive Belt Tensioner
39 (400, 29)
No.1 Timing Belt Cover
15.5 (158, 11)
39 (400, 29)
Generator Crankshaft Pulley
No.1 Idler Pulley Timing Belt L

34.5 (350, 25)
Plate Washer
Crankshaft Timing Pulley
34.5 (350, 25)
Timing Belt Guide (Crankshaft Angle Sensor Plate) Nm (kgfcm, ftlbf) : Specified torque L Precoated part
No.2 Idler Pulley Gasket Timing Belt Cover Spacer

A19486
Author :
Date :
1587
EM-20
EM0KX-06
NO !
INSPECTION
1. INSPECT TIMING BELT NOTICE: L Do not bend, twist or turn the timing belt inside out. L Do not allow the timing belt to contact with oil, water or steam. L Do not utilize timing belt tension when installing or removing the mount bolt of the camshaft timing pulley. If there any defects as shown in the illustrations, check these points: (a) Premature parting L Check for proper installation. L Check the timing cover gasket for damage and proper installation. (b) If the belt teeth are cracked or damaged, check if either camshaft is locked. (c) If there is noticeable wear or cracks on the belt face, check if there are nicks on the side of the idler pulley lock and the water pump. (d) Even if there is wear or damage on only one side of the belt, check the belt guide and the alignment of each pulley. (e) If there is noticeable wear on the belt teeth, check timing cover for damage and for foreign materials on the pulley teeth. If necessary, replace the timing belt.
EM3336
2. (a)
INSPECT IDLER PULLEYS Visually check the seal portion of the idler pulley for oil leakage. If leakage is found, replace the idler pulley. (b) Check that the idler pulley turns smoothly. If necessary, replace the idler pulley.
P20079
3. (a)
INSPECT TIMING BELT TENSIONER Visually check the seal portion of the tensioner for oil leakage.
HINT: If there is only the faintest trace of oil on the seal on the push rod side, the tensioner is all right. If leakage is found, replace the tensioner.
P20633
Author :
Date :
1593
EM-21
(b)
Hold the tensioner with both hands, and push the push rod strongly to check that it doesnt move. If the push rod moves, replace the tensioner. NOTICE: Never hold the tensioner push rod facing downward.
P20634
(c)
Protrusion
Measure the protrusion of the push rod from the housing end. Protrusion: 10.5 - 11.5 mm (0.413 - 0.453 in.) If the protrusion is not as specified, replace the tensioner. 4. INSPECT WATER PUMP (See page CO-7 )
P20635
Author :
Date :
1594
EM-22
EM0KY-09
INSTALLATION
Inward SST
1. (a) (b)
INSTALL CRANKSHAFT TIMING PULLEY Align the timing pulley set key with the key groove of the pulley. Using SST and a hammer, tap in the timing pulley, facing the flange side inward. SST 09223-4601 1
A04446
2. (a)
(b)
A04447
(c) (d)
INSTALL NO.1 IDLER PULLEY AND NO.2 IDLER PULLEY Apply adhesive 2 or 3 threads from the end of the pivot bolt. Adhesive: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent Using a 10 mm hexagon wrench, install the plate washer and the No.1 idler pulley with the pivot bolt. Torque: 34.5 Nm (350 kgfcm, 25 ftlbf) Install the No.2 idler pulley with the bolt. Torque: 34.5 Nm (350 kgfcm, 25 ftlbf) Check that the No.1 and No.2 idler pulley moves smoothly.
A04342
3. TEMPORARILY INSTALL TIMING BELT NOTICE: The engine should be cold. (a) Remove any oil or water on and clean the crankshaft pulley, the oil pump pulley, the water pump pulley, the No.1 idler pulley and the No.2 idler pulley. NOTICE: Only wipe the pulleys; do not use any cleansing agent. (b) Align the installation mark on the timing belt with the timing mark of the crankshaft timing pulley. (c) Install the timing belt on the crankshaft timing pulley, the No.1 idler pulley and the No.2 idler pulley. 4. INSTALL TIMING BELT COVER SPACER (a) Install the gasket to the cover spacer. (b) Install the cover spacer.
Author :
Date :
1595
EM-23
5. INSTALL TIMING BELT GUIDE Install the belt guide, facing the cup side outward. 6. INSTALL NO.1 TIMING BELT COVER Install the timing belt cover with the 4 bolts.
A04448
7. (a)
SST
A04449
INSTALL CRANKSHAFT PULLEY Align the pulley set key with the key groove of the crankshaft pulley. (b) Using SST and a hammer, tap in the crankshaft pulley. SST 09223-4601 1 8. INSTALL DRIVE BELT TENSIONER Install the belt tensioner with the bolt and the 2 nuts. Torque: 16 Nm (160 kgfcm, 12 ftlbf) HINT: Use a bolt of 106 mm (4.18 in.) in length. 9. INSTALL GENERATOR (See page CH-16 )
10. CHECK CRANKSHAFT PULLEY POSITION Check that the timing mark of the crankshaft pulley is aligned with the timing mark 0 of the No.1 timing belt cover.
A08660
SST
11. (a) (b)
INSTALL RH, LH CAMSHAFT TIMING PULLEYS Align the camshaft knock pin with the knock pin grove of the timing pulley, and slide on the timing pulley. Using SST, install the pulley bolt. SST 09960-10010 (09962-01000, 09963-01000) Torque: 108 Nm (1,100 kgfcm, 80 ftlbf)
A04340
Author :
Date :
1596
EM-24
12.
Turn
A04451
Turn
CONNECT TIMING BELT TO LH CAMSHAFT TIMING PULLEY (a) Remove any oil or water on the LH camshaft timing pulley, and clean it up. NOTICE: Only wipe the pulleys; do not use any cleansing agent. (b) Turn the LH camshaft timing pulley. Align the installation mark on the timing belt with the timing mark of the camshaft timing pulley, and hang the timing belt on the LH camshaft timing pulley. (c) Turn the LH camshaft timing pulley counterclockwise until there is tension between the crankshaft timing pulley and the LH camshaft timing pulley.
Tension
A04452
13.
Turn
A04453
1.27 mm Hex ago n Wrench

P20636
CONNECT TIMING BELT TO RH CAMSHAFT TIMING PULLEY (a) Remove any oil or water on the RH camshaft timing pulley and water pump pulley, and clean them up. NOTICE: Only wipe the pulleys; do not use any cleansing agent. (b) Turn the RH camshaft timing pulley. Align the installation mark on the timing belt with the timing mark of the camshaft timing pulley, and hang the timing belt on the RH camshaft timing pulley. 14. SET TIMING BELT TENSIONER (a) Using a press, slowly press in the push rod using 981 9,807 N (100 - 1,000 kgf, 220 - 2,205 lbf) of pressure. (b) Align the holes of the push rod and the housing, pass a 1.27 mm (0.050 in.) hexagon wrench through the holes to keep the setting position of the push rod. (c) Release the press. (d) Install the dust boot to the belt tensioner.
1.27 mm Hex ago n Wrench
15. (a) (b) (c)
INSTALL TIMING BELT TENSIONER Temporarily install the belt tensioner with the 2 bolts. Alternately tighten the 2 bolts. Torque: 26 Nm (270 kgfcm, 19 ftlbf) Using pliers, remove the 1.27 mm (0.050 in.) hexagon wrench from the belt tensioner.
A04454
Author :
Date :
1597
EM-25
16. (a) (b)
CHECK VALVE TIMING Temporarily install the crankshaft pulley bolt. Slowly turn the crankshaft pulley 2 revolutions from TDC to TDC. NOTICE: Always turn the crankshaft pulley clockwise.
Turn
A08597
(c)
Check that each pulley aligns with the timing marks as shown in the illustration. If the timing marks do not align, remove the timing belt and reinstall it.
A04335
17. TIGHTEN CRANKSHAFT PULLEY BOLT Using SST, install the pulley bolt. SST 09213-7001 1 (90105-70020), 09330-00021 Torque: 245 Nm (2,500 kgfcm, 181 ftlbf)
SST
A09156
A04455
18. INSTALL FAN BRACKET Install the fan bracket with the 2 bolts and the 2 nuts. Torque: 12 mm head 16 Nm (160 kgfcm, 12 ftlbf) 14 mm head 32 Nm (330 kgfcm, 24 ftlbf) HINT: Bolt Length: 106 mm (4.17 in.) for 12 mm head (A) 114 mm (4.49 in.) for 14 mm head (B) 19. INSTALL A/C COMPRESSOR (See page EM-81 )
Author :
Date :
1598
EM-26
20. INSTALL NO.2 TIMING BELT COVER Install the No.2 timing belt cover with the 2 bolts. Torque: 16 Nm (160 kgfcm, 12 ftlbf)
A04330
21. (a) (b)
INSTALL RH NO.3 TIMING BELT COVER Fit the RH No.3 timing belt cover, matching it with the fan bracket. Install the RH No.3 timing belt cover with the 3 bolts and nut. Torque: 7.5 Nm (80 kgfcm, 66 in.lbf)
A04329
22. (a) (b)
A04331
INSTALL LH NO.3 TIMING BELT COVER Install the oil cooler pipe and the bolt. Run the camshaft position sensor wire through the LH No.3 timing belt cover hole. (c) Fit the LH No.3 timing belt cover, matching it with the fan bracket. (d) Install the LH No.3 timing belt cover with the 4 bolts and the nut. Torque: 7.5 Nm (80 kgfcm, 66 in.lbf) (e) Install the wire grommet to the LH No.3 timing belt cover. (f) Install the sensor connector to the connector bracket. (g) Connect the sensor connector. (h) Install the sensor wire to the wire clamp on the LH No.3 timing belt cover. (i) Install the engine wire to the 2 wire clamps on the LH No.3 timing belt cover. 23. INSTALL DRIVE BELT IDLER PULLEY Install the idler pulley and the cover plate with the bolt. Torque: 37 Nm (380 kgfcm, 27 ftlbf) 24. INSTALL RADIATOR ASSEMBLY (See page CO-19 )
Author :
Date :
1599
EM-27
25. (a) (b) (c)

A02247
26. 27. 28. 29. 30. 31. 32. 33.
INSTALL FAN PULLEY, FAN, FLUID COUPLING AND DRIVE BELT Temporarily install the fan pulley, the fan, fluid coupling assembly with the 4 nuts. Install the generator drive belt. (See page CH-16 ) Tighten the 4 nuts holding the fluid coupling to the fan bracket. Torque: 21 Nm (215 kgfcm, 16 ftlbf) INSTALL AIR CLEANER AND INTAKE AIR CONNECTOR ASSEMBLY INSTALL V-BANK COVER FILL WITH ENGINE COOLANT START ENGINE AND CHECK FOR LEAKS RECHECK ENGINE COOLANT LEVEL INSTALL BATTERY CLAMP COVER INSTALL ENGINE UNDER COVER INSTALL OIL PAN PROTECTOR
Author :
Date :
1600
EM-15
EM1VA-01
REMOVAL
REMOVE OIL PAN PROTECTOR REMOVE ENGINE UNDER COVER DRAIN ENGINE COOLANT REMOVE BATTERY CLAMP COVER REMOVE V-BANK COVER Remove the fuel return hose from the V-bank cover. Remove the 2 bolt, 2 cap nuts and V-bank cover. REMOVE AIR CLEANER AND INTAKE AIR CONNECTOR ASSEMBLY 7. REMOVE DRIVE BELT, FAN, FLUID COUPLING AND FAN PULLEY (a) Loosen the 4 nuts holding the fluid coupling to the fan bracket. (b) Remove the generator drive belt. (See page CH-7 ) (c) Remove the 4 nuts, the fan, the fluid coupling assembly and the fan pulley. 8. REMOVE RADIATOR ASSEMBLY (See page CO-17 ) 9. REMOVE DRIVE BELT IDLER PULLEY Remove the pulley bolt, the cover plate and the idler pulley. 1. 2. 3. 4. 5. (a) (b) 6.
A02247
10. REMOVE RH NO.3 TIMING BELT COVER Remove the 3 bolts, the nut and the RH No.3 timing belt cover.
A04329
Author :
Date :
1588
EM-16
11. (a) (b) (c) (d) (e) (f) (g) (h)
A04331
REMOVE LH NO.3 TIMING BELT COVER Disconnect the engine wire from the 2 wire clamps. Remove the 4 bolts and the nut. Disconnect the camshaft position sensor wire from the wire clamp on the LH No.3 timing belt cover. Disconnect the sensor connector from the connector bracket. Disconnect the camshaft position sensor connector. Remove the wire grommet from the LH No.3 timing belt cover. Remove the LH No.3 timing belt cover. Remove the oil cooler pipe and the 2 bolts.
12. REMOVE NO.2 TIMING BELT COVER Remove the 2 bolts and the No.2 timing belt cover. 13. DISCONNECT A/C COMPRESSOR FROM ENGINE (See page EM-77 )
A04330
14. REMOVE FAN BRACKET Remove the 2 bolts, the 2 nuts and the fan bracket.
A04455
15.
IF RE-USING TIMING BELT, CHECK INSTALLATION MARKS ON TIMING BELT Check that there are 3 installation marks on the timing belt as turning the crankshaft pulley as shown in the illustration. HINT: If the installation marks are disappeared, place a new installation mark on the timing belt before removing each part.
A04332
Author :
Date :
1589
EM-17
16. LOOSEN CRANKSHAFT PULLEY BOLT Using SST, loosen the pulley bolt. SST 09213-7001 1 (90105-70020), 09330-00021
SST
A09156
17. (a)
SET NO.1 CYLINDER TO TDC/COMPRESSION Turn the crankshaft pulley and align its groove with the timing mark 0 of the No.1 timing belt cover.
Turn
A08597
Check that the timing marks of the camshaft timing pulleys and that of the timing belt rear plates aligned. If not, turn the crankshaft 1 revolution (360). (c) Remove the crankshaft pulley bolt. NOTICE: Do not turn the crankshaft pulley.
(b)
A04335
18. REMOVE TIMING BELT TENSIONER HINT: L When re-using timing belt: If the installation marks are disappeared, place 2 new installation marks on the timing belt to match the timing marks of the camshaft timing pulleys before the removal.
A04337
When replacing timing belt tensioner only: To avoid meshing of the timing pulley and the timing belt, secure one of them with string, and then place matchmarks on the timing belt and the RH camshaft timing pulley.
String
A04338
Author :
Date :
1590
EM-18
Alternately loosen the 2 bolts, and remove the belt tensioner and the dust boot.
A04339
19.
Slightly Turn
(a)
(b)
A05707
DISCONNECT TIMING BELT FROM CAMSHAFT TIMING PULLEYS Using SST, loosen the tension spring between the LH and RH camshaft timing pulleys by slightly turning the LH camshaft timing pulley clockwise. SST 09960-10010 (09962-01000, 09963-01000) Disconnect the timing belt from the camshaft timing pulleys.
SST
20. REMOVE CAMSHAFT TIMING PULLEYS Using SST, remove the bolt and the timing pulley. Remove the 2 timing pulleys. SST 09960-10010 (09962-01000, 09963-01000) 21. REMOVE GENERATOR (See page CH-7 ) 22. REMOVE DRIVE BELT TENSIONER Remove the bolt, 2 nuts and the belt tensioner.
A04340
SST
A04341
23. REMOVE CRANKSHAFT PULLEY Using SST, remove the crankshaft pulley. SST 09950-50013 (09951-05010, 09952-05010, 09953-05010, 09954-05011, 09953-05020, 09954-05021) NOTICE: Do not turn the crankshaft pulley. 24. REMOVE NO.1 TIMING BELT COVER Remove the 4 bolts and the timing belt cover. 25. 26. REMOVE TIMING BELT GUIDE REMOVE TIMING BELT COVER SPACER
A04448
Author :
Date :
1591
EM-19
27. REMOVE TIMING BELT HINT: If re-using the belt and the installation mark is disappeared from it, place a new installation mark on the timing belt to the match the dot mark on the crankshaft timing pulley.
A04342
28. (a) (b)
REMOVE NO.1 IDLER PULLEY AND NO.2 IDLER PULLEY Using a 10 mm hexagon wrench, remove the bolt, the No.1 idler pulley and the plate washer. Remove the bolt and the No.2 idler pulley.
A04444
29. REMOVE CRANKSHAFT TIMING PULLEY Using SST, remove the timing pulley. SST 09950-50013 (09951-05010, 09952-05010, 09953-05010, 09953-05020, 09954-05011, 09954-05021) NOTICE: Do not turn the timing pulley.
SST
A04445
Author :
Date :
1592
EM-4
ENGINE MECHANICAL VALVE CLEARANCE
VALVE CLEARANCE
EM0KS-08
INSPECTION
HINT: Inspect and adjust the valve clearance when the engine is cold. 1. DRAIN ENGINE COOLANT 2. REMOVE BATTERY CLAMP COVER 3. REMOVE V-BANK COVER 4. REMOVE AIR CLEANER AND INTAKE AIR CONNECTOR ASSEMBLY 5. REMOVE NO.3 TIMING BELT COVERS (See page EM-15 ) 6. REMOVE IGNITION COILS (See page IG-6 ) 7. REMOVE RH CYLINDER HEAD COVER Remove the 9 bolts, the 9 seal washers and the cylinder head cover. 8. REMOVE LH CYLINDER HEAD COVER (a) Remove the oil dipstick for the transmission. (b) Disconnect the PCV hose. (c) Disconnect the engine wire clamp from the wire bracket on the cylinder head cover. (d) Remove the 9 bolts, the 9 seal washers and the cylinder head cover.
9. (a)
SET NO.1 CYLINDER TO TDC/COMPRESSION Turn the crankshaft pulley, and align its groove with timing mark 0 of the No.1 timing belt cover.
A04324
(b)
Check that the timing marks of the camshaft timing pulleys and that of the timing belt rear plates are aligned. If not, turn the crankshaft 1 revolution (360) and align the mark as above.
A04325
Author :
Date :
1577
EM-5
RH Cylinder Head
10. (a)
LH Cylinder Head
Front
INSPECT VALVE CLEARANCE Check only the valves indicated. L Using a feeler gauge, measure the clearance between the valve lifter and the camshaft. L Record the out-of-specification valve clearance measurements. They will be used later to determine the required replacement adjusting shim. Valve clearance (Cold): Intake 0.15 - 0.25 mm (0.006 - 0.010 in.) Exhaust 0.25 - 0.35 mm (0.010 - 0.014 in.)
A05717
(b)
RH Cylinder Head
(c) 11. (a) (b) (c)

Front
Turn the crankshaft 1 revolution (360) and align the mark as above (See procedure in step 9). Check only the valves indicated as shown. Measure the valve clearance. (See procedure in step (a)) ADJUST VALVE CLEARANCE Remove the timing belt (See page EM-15 ). Remove the camshafts (See page EM-35 ). Remove the valve lifter and adjusting shim.
LH Cylinder Head
A04457
(d)
A02213
Determine the replacement adjusting shim size according to the following Formula and Charts: L Using a micrometer, measure the thickness of the removed shim. L Calculate the thickness of a new shim so that the valve clearance comes within the specified value. T ........... Thickness of removed shim A ........... Measured valve clearance N ........... Thickness of new shim
Author :
Date :
1578
EM-6
Intake: N = T + (A - 0.20 mm (0.008 in.)) Exhaust: N = T + (A - 0.30 mm (0.012 in.)) L Select a new shim with the closest thickness as close as possible to the calculated value. HINT: Shims are available in 41 increments of 0.020 mm (0.0008 in.), from 2.00 mm (0.0787 in.) to 2.80 mm (0.1102 in.). (e) Place a new adjusting shim on the valve. (f) Place the valve lifter. (g) Reinstall the camshafts (See page EM-57 ). (h) Reinstall the timing belt (See page EM-22 ). (i) Recheck the valve clearance. 12. REINSTALL CYLINDER HEAD COVERS 13. REINSTALL IGNITION COILS 14. REINSTALL NO.3 TIMING BELT COVERS (See page EM-22 ) 15. REINSTALL AIR CLEANER AND INTAKE AIR CONNECTOR ASSEMBLY 16. REFILL WITH ENGINE COOLANT 17. START ENGINE AND CHECK FOR LEAKS 18. RECHECK ENGINE COOLANT LEVEL 19. REINSTALL V-BANK COVER 20. REINSTALL BATTERY CLAMP COVER
Author :
Date :
1579
Adjusting Shim Selection Chart (Intake)

Installed shim thickness mm (in.)
Measured clearance mm (in.)
Author :
Shim No. Thickness
New shim thickness

Shim No. Thickness Shim No.
mm (in.)
Thickness
Date : 1580
A03111
Intake valve clearance (Cold): 0.15 - 0.25 mm (0.006 - 0.010 in.)
EXAMPLE: The 2.300 mm (0.0906 in.) shim is installed, and the measured clearance is 0.440 mm (0.0173 in.). Replace the 2.300 mm (0.0906 in.) shim with a No. 54 shim.
EM-7
EM-8
Adjusting Shim Selection Chart (Exhaust)

Installed shim thickness mm (in.)
Measured clearance mm (in.)
Author :
Shim No. Thickness
New shim thickness

Shim No. Thickness Shim No.
mm (in.)
Thickness
Date :
A03112
Exhaust valve clearance (Cold): 0.25 - 0.35 mm (0.010 - 0.014 in.)
EXAMPLE: The 2.300 mm (0.0906 in.) shim is installed, and the measured clearance is 0.440 mm (0.0173 in.). Replace the 2.300 mm (0.0906 in.) shim with a No. 44 shim.
1581

Engine Mechanical PDF

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Engine Mechanical PDF

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EM-1

ENGINE MECHANICAL CO/HC

2004 LAND CRUISER (RM1071U)

Rough idle (fluctuating HC reading)

Rough idle (Black smoke from exhaust)

2004 LAND CRUISER (RM1071U)

3. (a) (b) (c)

2004 LAND CRUISER (RM1071U)

Water Bypass Pipe z O-Ring Water Pump Engine Wire

x5 Engine Mounting Bracket

z Gasket Knock Sensor 2 Engine Coolant Drain Union Knock Sensor 1

30.5 (310, 22)

Oil Pump z O-Ring

z Crankshaft Front Oil Seal

L Engine Coolant Drain Union z Gasket Crankshaft Position Sensor Connector

Engine Wire Cover

Engine Mounting Bracket

Oil Strainer Oil Pressure Sender Gauge Connector Clamp z Tape

No.1 Oil Pan

7.5 (80, 66 in.lbf)

28 (290, 31) 7.5 (80, 66 in.lbf)

Oil Pan Baffle Plate

No.2 Oil Pan

Nm (kgfcm, ftlbf) : Specified torque z Non-reusable part L Precoated part

z Gasket Drain Plug

2004 LAND CRUISER (RM1071U)

Connecting Rod Bearing

Connecting Rod Cap

z Crankshaft Rear Oil Seal

Rear Oil Seal Retainer

Upper Crankshaft Thrust Washer

Upper Main Bearing

Lower Main Bearing

Lower Crankshaft Thrust Washer

Main Bearing Cap

See page EM-107 1st 27 (275, 20) 2nd Turn 90

Nm (kgfcm, ftlbf) : Specified torque z Non-reusable part

Pull Wire Clamp O-Ring

4. (a) (b) (c) (d) 5. 6.

2004 LAND CRUISER (RM1071U)

18. (a) (b) (c)

20. (a) (b)

2004 LAND CRUISER (RM1071U)

Lay a strip of plastigage across the crank pin.

Number Mark No.4 No.3 No.1 No.2

Number Mark Number Mark

EXAMPLE: Connecting rod cap 3 + Crankshaft 1 = Total number 4 (Use bearing 4)

A05852 A05087 A05853

2004 LAND CRUISER (RM1071U)

Reference Connecting rod big end inside diameter:

Crankshaft crank pin diameter:

Standard sized bearing center wall thickness:

(j) 21. (a) (b) HINT:

2004 LAND CRUISER (RM1071U)

2004 LAND CRUISER (RM1071U)

No.4 No.5 Number Mark No.2 No.1 Number Mark

No.5 No.2 No.1 No.3 No.4 Number Mark

Cylinder block (A) + Crankshaft (B)

A05089 A05088 A05090

Cylinder block (A) + Crankshaft (B)

EXAMPLE: Cylinder block 08 + Crankshaft 06 = Total number 14 (Use bearing 3)

Reference Cylinder block main journal bore diameter (A):

Mark 08 Mark 09 Mark 10 Mark 11 Mark 12 Mark 13 Mark 14 Mark 15 Mark 16

Crankshaft main journal diameter (B):

Standard bearing center wall thickness: No.1 and No.5

Completely remove the plastigage.

2004 LAND CRUISER (RM1071U)

24. (a) (b)

Gradually heat the piston to approx. 60C (140F).

2004 LAND CRUISER (RM1071U)

2004 LAND CRUISER (RM1071U)

Cylinder Block Side

Main Bearing Cap Side

A04850 A04210 A04212

2004 LAND CRUISER (RM1071U)

Thrust Direction Axial Direction