engine TOYOTA LAND CRUISER 1996 J80 Workshop Manual

EM−80
−
ENGINE MECHANICAL ENGINE UNIT
1996 LAND CRUISER (RM451U)
19. CONNECT ENGINE WIRE TO CABIN
(a) Push in the engine wire through the cowl panel.
(b) Connect the connectors.
(1) Connect the 3 connectors to the ECM.
(2) Connect the 2 connectors to the cowl wire.
(c) Connect the A/C amplifier with the screw.
(d) Install the speaker panel with the screw.
(e) Install the glove compartment door with the 2 screws.
20. CONNECT PS RETURN HOSE
Connect the return hose to the PS reservoir tank.
21. CONNECT PS PRESSURE HOSE
Connect the PS pressure hose with 2 new gaskets and the
union bolt. Torque: 56 N·m (575 kgf·cm, 42 ft·lbf)
22. INSTALL RADIATOR PIPE
(a) Connect the No. 2 radiator hose to the water inlet.
(b) Install the 2 nuts holding the radiator pipe to the No. 1 oil pan.
Torque: 21 N·m (210 kgf·cm, 15 ft·lbf)
23. INSTALL A/C COMPRESSOR AND BRACKET
(a) Install the A/C compressor bracket with the 5 bolts.
Torque: 37 N·m (375 kgf·cm, 27 ft·lbf)
(b) Install the A/C compressor with the 4 bolts. Torque: 25 N·m (250 kgf·cm, 18 ft·lbf)
(c) Install and adjust the drive belt (See page CH−2).
24. CONNECT WIRES AND CONNECTORS
(a) Connect the 2 heated oxygen sensor connectors.
(b) Connect the DLC1 clamp.
(c) Connect the 2 oil pressure gauge connectors.
(d) Connect the generator wire and connector.
(e) Connect the connector on the intake manifold to the fend-
er apron.
(f) Connect the high −tension cord to the ignition coil.
(g) Connect the ground strap to the No. 1 engine hanger.
(h) Connect the ground strap to the air intake chamber.
(i) Connect the starter wire.
(j) Connect the ground cable to the cylinder block.
25. CONNECT FUEL HOSES
(a) Connect the fuel inlet hose to the fuel filter with 2 new gas-
kets and the union bolt.
Torque: 29 N·m (300 kgf·cm, 22 ft·lbf)
(b) Connect the fuel return hose.
Brought to you by BirfMark
Brought to you by BirfMark
Version 1.11 - 03/16/2010

−
ENGINE MECHANICAL ENGINE UNIT
EM−81
1996 LAND CRUISER (RM451U)
26. CONNECT EVAP HOSE
27. CONNECT BRAKE BOOSTER VACUUM HOSE
28. CONNECT HEATER VALVE AND ENGINE WIRE TO
COWL PANEL
(a) Connect the heater valve with the 2 bolts.
(b) Connect the engine wire and ground strap with the 2 bolts.
29. CONNECT HEATER HOSES
30. CONNECT ACCELERATOR CABLE TO THROTTLE BODY
31. CONNECT CRUISE CONTROL ACTUATOR CABLE TO
THROTTLE BODY
32. INSTALL AIR CLEANER CASE
33. INSTALL AIR CLEANER HOSE AND CAP
34. CONNECT OIL COOLER HOSE TO OIL COOLER PIPE
35. INSTALL RADIATOR (See page CO−16)
36. INSTALL RADIATOR GRILLE
Install the radiator grille with the 5 screws and clip.
37. INSTALL BATTERY TRAY AND BATTERY
(a) Install the battery tray with the 5 bolts.
(b) Connect the ground strap with the bolt.
(c) Install the battery and hold−down clamp with the nuts.
(d) Connect the battery cables.
38. FILL WITH ENGINE OIL
39. FILL RADIATOR WITH ENGINE COOLANT
40. START ENGINE AND CHECK FOR LEAKS
41. CHECK AUTOMATIC TRANSMISSION FLUID LEVEL
42. CHECK IGNITION TIMING (See page EM−10)
43. INSTALL HOOD
44. PERFORM ROAD TEST
Check for abnormal noise, shock, slippage, correct shift points
and smooth operation.
45. RECHECK ENGINE COOLANT AND ENGINE OIL LEV-
ELS
Brought to you by BirfMark
Brought to you by BirfMark
Version 1.11 - 03/16/2010

EM1EF−01
EM−82
−
ENGINE MECHANICAL CYLINDER BLOCK
585
Author: Date:
1996 LAND CRUISER (RM451U)
CYLINDER BLOCK
COMPONENTS
Brought to you by BirfMark
Brought to you by BirfMark
Version 1.11 - 03/16/2010

EM1Q8−01
−
ENGINE MECHANICAL CYLINDER BLOCK
EM−83
1996 LAND CRUISER (RM451U)
DISASSEMBLY
1. REMOVE DRIVE PLATE
Uniformly loosen and remove the drive plate bolts, in several
passes, in the sequence shown.
2. INSTALL ENGINE TO ENGINE STAND FOR DIS-
ASSEMBLY
3. REMOVE CYLINDER HEAD (See page EM−28 )
4. REMOVE TIMING CHAIN AND GEARS (See page EM−13 )
5. REMOVE OIL FILTER (See page LU−2)
6. REMOVE OIL FILTER UNION
7. REMOVE KNOCK SENSORS
Using SST, remove the 2 knock sensors. SST 09816−30010
8. REMOVE PS PUMP
(a) Remove the 2 nuts and pump.
(b) Remove the O−ring from the pump.
Brought to you by BirfMark
Brought to you by BirfMark
Version 1.11 - 03/16/2010

EM−84
−
ENGINE MECHANICAL CYLINDER BLOCK
1996 LAND CRUISER (RM451U)
9. REMOVE RH ENGINE MOUNTING BRACKET
(a) Remove the nut and insulator.
(b) Remove the 4 bolts and bracket.
10. REMOVE LH ENGINE MOUNTING BRACKET
(a) Remove the nut and insulator.
(b) Remove the 4 bolts and bracket.
11. REMOVE OIL COOLER COVER AND OIL COOLER
Remove the 10 bolts, 2 nuts, oil cooler cover with the oil cooler
and gasket.
12. REMOVE REAR OIL SEAL RETAINER
Remove the 4 bolts and retainer.
13. CHECK CONNECTING ROD THRUST CLEARANCE
Using a dial indicator, measure the thrust clearance while mov-
ing the connecting rod back and forth.
Standard thrust clearance:
0.160 − 0.262 mm (0.0063 − 0.0103 in.)
Maximum thrust clearance: 0.362 mm (0.0143 in.)
If the thrust clearance is greater than maximum, replace the
connecting rod assembly. If necessary , replace the crankshaft.
Brought to you by BirfMark
Brought to you by BirfMark
Version 1.11 - 03/16/2010

−
ENGINE MECHANICAL CYLINDER BLOCK
EM−85
1996 LAND CRUISER (RM451U)
14. REMOVE CONNECTING ROD CAPS AND CHECK OIL
CLEARANCE
(a) Check the matchmarks on the connecting rod cap and
connecting rod to ensure correct reassembly.
(b) Remove the connecting rod cap nuts.
(c) Using a plastic− faced hammer, lightly tap the connecting
rod bolts and lift off the connecting rod cap.
HINT:
Keep the lower bearing inserted with the connecting rod cap.
(d) Cover the connecting rod bolts with a short piece of hose to protect the crankshaft from damage.
(e) Clean the crank pin and bearing.
(f) Check the crank pin and bearing for pitting and scratches.
If the crank pin or bearing is damaged, replace the bearings. If
necessary, grind or replace the crankshaft.
(g) Lay a strip of Plastigage across the crank pin.
Brought to you by BirfMark
Brought to you by BirfMark
Version 1.11 - 03/16/2010

EXAMPLE: Connecting rod ”3” + Crankshaft ”1”= Total number 4 (Use bearing ”4”)
Number marked
Connecting rod
Crankshaft
Use bearing 123
2
2 22
3
3 3
3 3
4445 56
111
EM−86
−
ENGINE MECHANICAL CYLINDER BLOCK
1996 LAND CRUISER (RM451U)
(h) Install the connecting rod cap with the 2 nuts (See page EM−103 ).
NOTICE:
Do not turn the crankshaft.
(i) Remove the 2 nuts and connecting rod cap (See proce-
dure (b) and (c) above).
(j) Measure the Plastigage at its widest point. Standard oil clearance:
STD0.032 − 0.050 mm (0.0013 − 0.0020 in.)
U/S 0.250.033 − 0.073 mm (0.0013 − 0.0029 in.)
Maximum oil clearance: 0.10 mm (0.0039 in.)
If the oil clearance is greater than maximum, replace the bear-
ings. If necessary, grind or replace the crankshaft.
HINT:
If using a standard bearing, replace with one having the same
number. If the number of the bearing cannot be determined, se-
lect the correct bearing by adding together the numbers im-
printed on the connecting rod and crankshaft, then selecting
the bearing with the same number as the total. There are 5 sizes
of standard bearings, marked ”2”, ”3”, ”4”, ”5” and ”6” according-
ly.
Reference
Connecting rod big end inside diameter:
Mark ”1”60.526 − 60.532 mm (2.3829 − 2.3831 in.)
Mark ”2”60.532 − 60.538 mm (2.3831 − 2.3834 in.)
Mark ”3”60.538 − 60.544 mm (2.3834 − 2.3836 in.)
Crankshaft crank pin diameter:
Mark ”1”56.994 − 57.000 mm (2.2439 − 2.2441 in.)
Mark ”2”56.988 − 56.994 mm (2.2436 − 2.2439 in.)
Mark ”3”56.982 − 56.988 mm (2.2434 − 2.2436 in.)
Brought to you by BirfMark
Brought to you by BirfMark
Version 1.11 - 03/16/2010

P04620
−
ENGINE MECHANICAL CYLINDER BLOCK
EM−87
1996 LAND CRUISER (RM451U)
Standard sized bearing center wall thickness:
Mark ”2”1.744 − 1.747 mm (0.0687 − 0.0688 in.)
Mark ”3”1.747 − 1.750 mm (0.0688 − 0.0689 in.)
Mark ”4”1.750 − 1.753 mm (0.0689 − 0.0690 in.)
Mark ”5”1.753 − 1.756 mm (0.0690 − 0.0691 in.)
Mark ”6”1.756 − 1.759 mm (0.0691 − 0.0693 in.)
(k) Completely remove the Plastigage.
15. R E M O V E P I S TO N A N D C O N N E C T I N G R O D A S-
SEMBLIES
(a) Using a ridge reamer, remove the all carbon from the top of the cylinder.
(b) Push the piston, connecting rod assembly and upper bearing through the top of the cylinder block.
HINT:
Keep the bearings, connecting rod and cap together.
Arrange the piston and connecting rod assemblies in cor-
rect order.
16. 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 maximum, replace the
thrust washers as a set. Thrust washer thickness:
STD2.440 − 2.490 mm (0.0961 − 0.0980 in.)
O/S 0.1252.503 − 2.553 mm (0.0985 − 0.1005 in.)
O/S 0.2502.565 − 2.615 mm (0.1010 − 0.1030 in.)
17. REMOVE MAIN BEARING CAPS AND CHECK OIL
CLEARANCE
(a) Uniformly loosen and remove the main bearing cap bolts
in several passes, in the sequence shown.
Brought to you by BirfMark
Brought to you by BirfMark
Version 1.11 - 03/16/2010

EM−88
−
ENGINE MECHANICAL CYLINDER BLOCK
1996 LAND CRUISER (RM451U)
(b) Using the removed main bearing cap bolts, pry the main
bearing cap back and forth, and remove the main bearing
caps, lower bearings and (No.4 main bearing cap only)
lower thrust washers.
HINT:
Keep the lower bearing and main bearing cap together.
Arrange the main bearing caps and lower thrust washers
in correct order.
(c) Lift out the crankshaft.
HINT:
Keep the upper bearing and 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, grind or replace the crankshaft.
(f) Place the crankshaft on the cylinder block.
(g) Lay a strip of Plastigage across each journal.
(h) Install the main bearing caps (See page EM−103).
NOTICE:
Do not turn the crankshaft.
(i) Remove the main bearing caps (See procedure (a) and (b) above).
Brought to you by BirfMark
Brought to you by BirfMark
Version 1.11 - 03/16/2010

EXAMPLE: Cylinder block ”2” + Crankshaft ”1”= Total number 3 (Use bearing ”3”)
Number marked
Cylinder block
Crankshaft
Use bearing 123
2
2 22
3
3 3
3 3
4445 56
111
−
ENGINE MECHANICAL CYLINDER BLOCK
EM−89
1996 LAND CRUISER (RM451U)
(j) Measure the Plastigage at its widest point.
Standard clearance:
STD0.042 − 0.060 mm (0.0017 − 0.0024 in.)
U/S 0.250.041 − 0.081 mm (0.0016 − 0.0032 in.)
Maximum clearance: 0.10 mm (0.0039 in.)
If the oil clearance is greater than maximum, replace the bear-
ings. If necessary, grind or replace the crankshaft.
HINT:
If using a standard bearing, replace with one having the same
number. If the number of the bearing cannot be determined, se-
lect the correct bearing by adding together the numbers im-
printed on the cylinder block and crankshaft, then selecting the
bearing with the same number as the total. There are 5 sizes
of standard bearings, marked ”2”, ”3”, ”4”, ”5” and ”6”\
accorking-
ly.
Reference
Cylinder block main journal bore diameter:
Mark ”1”74.026 − 74.032 mm (2.9144 − 2.9146 in.)
Mark ”2”74.032 − 74.038 mm (2.9146 − 2.9149 in.)
Mark ”3”74.038 − 74.044 mm (2.9149 − 2.9151 in.)
Crankshaft main journal diameter:
Mark ”1”68.994 − 69.000 mm (2.7163 − 2.7165 in.)
Mark ”2”68.988 − 68.994 mm (2.7161 − 2.7163 in.)
Mark ”3”68.982 − 68.988 mm (2.7158 − 2.7161 in.)
Standard bearing center wall thickness:
Mark ”2”2.489 − 2.492 mm (0.0980 − 0.0981 in.)
Mark ”2”2.492 − 2.495 mm (0.0981 − 0.0982 in.)
Mark ”3”2.495 − 2.498 mm (0.0982 − 0.0983 in.)
Mark ”4”2.498 − 2.501 mm (0.0983 − 0.0985 in.)
Mark ”5”2.501 − 2.504 mm (0.0985 − 0.0986 in.)
(k) Completely remove the Plastigage.
18. REMOVE CRANKSHAFT
(a) Lift out the crankshaft.
(b) Remove the upper main bearings and upper thrust wash-
ers from the cylinder block.
HINT:
Arrange the main bearings and thrust washers in correct order.
Brought to you by BirfMark
Brought to you by BirfMark
Version 1.11 - 03/16/2010