TOYOTA LAND CRUISER 1996 J80 Workshop Manual

EM3322
EM−46
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ENGINE MECHANICAL CYLINDER HEAD
1996 LAND CRUISER (RM451U)
(e) Inspect the gear spring
Using vernier calipers, measure the free distance be-
tween the spring ends.
Free distance: 18.2 − 18.8 mm (0.717 − 0.740 in.)
If the free distance is not as specified, replace the gear spring.
(f) Inspect the journal oil clearance. (1) Clean the bearing caps and camshaft journals.
(2) Place the camshafts on the cylinder head.
(3) Lay a strip of Plastigage across each of the cam-
shaft journals.
(4) Install the bearing caps (See page EM−54).
NOTICE:
Do not turn the camshaft. (5) Remove the bearing caps.
(6) Measure the Plastigage at its widest point.
Standard oil clearance:
0.025 − 0.062 mm (0.0010 − 0.0024 in.)
Maximum oil clearance: 0.10 mm (0.0039 in.)
If the oil clearance is greater than maximum, replace the cam-
shaft. If necessary, replace the bearing caps and cylinder head
as a set. (7) Completely remove the Plastigage.
(g) Inspect the thrust clearance. (1) Install the camshaft (See page EM−54 ).
(2) Using a dial indicator, measure the thrust clearance
while moving the camshaft back and forth.
Standard thrust clearance:
0.030 − 0.080 mm (0.0012 − 0.0031 in.)
Maximum thrust clearance: 0.10 mm (0.0039 in.)
If the thrust clearance is greater than maximum, replace the
camshaft. If necessary, replace the bearing caps and cylinder
head as a set.
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EM2196
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ENGINE MECHANICAL CYLINDER HEAD
EM−47
1996 LAND CRUISER (RM451U)
(h) Inspect the gear backlash.
(1) Install the camshafts without installing the exhaustcam sub−gear (See page EM−54).
(2) 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 maximum, replace the cam-
shafts.
10. INSPECT VALVE LIFTER OIL CLEARANCE
(a) Using a caliper gauge, measure the lifter bore diameter of the cylinder head.
Lifter bore diameter:
34.000 − 34.021 mm (1.3386 − 1.3394 in.)
(b) Using a micrometer, measure the lifter diameter. Lifter diameter:
33.966 − 33.976 mm (1.3372 − 1.3376 in.)
(c) Subtract the lifter diameter measurement from the lifter bore diameter measurement.
Standard oil clearance:
0.024 − 0.055 mm (0.0009 − 0.0022 in.)
Maximum oil clearance: 0.07 mm (0.0028 in.)
If the oil clearance is greater than maximum, replace the lifter.
If necessary, replace the cylinder head.
11. INSPECT AIR INTAKE CHAMBER
Using a precision straight edge and thickness gauge, measure
the surface contacting the intake manifold for warpage. Maximum warpage: 0.30 mm (0.0118 in.)
If warpage is greater than maximum, replace the air intake
chamber.
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P22604
EM−48
−
ENGINE MECHANICAL CYLINDER HEAD
1996 LAND CRUISER (RM451U)
12. INSPECT INTAKE MANIFOLD
Using a precision straight edge and thickness gauge, measure
the surface contacting the cylinder head and air intake chamber
for warpage.
Maximum warpage: 0.30 mm (0.0118 in.)
If warpage is greater than maximum, replace the manifold.
13. INSPECT EXHAUST MANIFOLDS
Using a precision straight edge and thickness gauge, measure
the surface contacting the cylinder head for warpage. Maximum warpage: 0.30 mm (0.0118 in.)
If warpage is greater than maximum, replace the manifold.
14. INSPECT CHAIN TENSIONER
Check that the plunger moves smoothly.
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EM1Q6−01
Both intake and exhaust
Bushing bore diametermm (in.)Bushing
size
11.492 − 11.513
(0.4524 − 0.4533)
11.542 − 11.563
(0.4544 − 0.4552) Use STD
Use O/S 0.05
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ENGINE MECHANICAL CYLINDER HEAD
EM−49
1996 LAND CRUISER (RM451U)
REPLACEMENT
1. REPLACE VALVE GUIDE BUSHINGS
(a) Gradually heat the cylinder head to 80 − 100°C (176 −
212 °F).
(b) Using SST and a hammer, tap out the guide bushing. SST 09201 −10000 (09201 −01070), 09950 −70010
(09951 −07100)
(c) Using a caliper gauge, measure the bushing bore diame- ter of the cylinder head.
(d) Select a new guide bushing (STD or O/S 0.05).
If the bushing bore diameter of the cylinder head is greater than
11.513 mm (0.4533 in.), machine the bushing bore to the follow-
ing dimension: 11.542 − 11.563 mm (0.4544 − 0.4552 in.)
If the bushing bore diameter of the cylinder head is greater than
11.563 mm (0.4552 in.), replace the cylinder head.
(e) Gradually heat the cylinder head to 80 − 100°C (176 −
212 °F).
(f) Using SST and a hammer, tap in a new guide bushing un-
til it protrudes 8.2 − 8.6 mm (0.323 − 0.339 in.) from the
cylinder head.
SST 09201 −10000 (09201 −01070), 09950 −70010
(09951 −07100)
(g) Using a sharp 7 mm reamer, ream the guide bushing to obtain the standard specified clearance (See page
EM−40 ) between the guide bushing and valve stem.
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EM−50
−
ENGINE MECHANICAL CYLINDER HEAD
1996 LAND CRUISER (RM451U)
2. REPLACE SPARK PLUG TUBE GASKETS
(a) Using a screwdriver, pry out the tube gasket.
(b) Using SST and a hammer, tap in a new tube gasket as
shown in the illustration.
SST 09950 −60010 (09951 −00480), 09950 −70010
(09951 −07150)
(c) Apply a light coat of MP grease to the gasket lip.
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EM1E6−01
−
ENGINE MECHANICAL CYLINDER HEAD
EM−51
1996 LAND CRUISER (RM451U)
REASSEMBLY
HINT:
Thoroughly clean all parts to be assembled.
Before installing the parts, apply new engine oil to all slid-
ing and rotating surfaces.
Replace all gaskets and oil seals with new ones.
1. INSTALL SPARK PLUG TUBES
HINT:
When using a new cylinder head, spark plug tubes must be
installed.
(a) Mark the standard position away from the edge, onto the spark plug tube.
Standard protrusion: 45.5 mm (1.791 in.)
(b) Apply adhesive to the spark plug tube hole of the cylinder
head.
Sealant:
Part No. 08833−00070, Adhesive 1324, THREE BOND
1324 or equivalent
(c) Using a press, press in a new spark plug tube until there is 45.5 mm (1.791 in.) protruding from the camshaft bear-
ing cap installation surface of the cylinder head.
NOTICE:
Avoid pressing a new spark plug tube in too far by measur-
ing the amount of protrusion while pressing.
2. INSTALL TVV
(a) Apply adhesive to 2 or 3 threads of the TVV. Adhesive:
Part No.08833 −00080, THREE BOND 1344, LOCTITE
242 or equivalent
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EM−52
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ENGINE MECHANICAL CYLINDER HEAD
1996 LAND CRUISER (RM451U)
(b) Install the TVV.
3. INSTALL ECT SENDER GAUGE
4. INSTALL ECT CUT SWITCH
5. INSTALL ECT SENSOR
6. INSTALL VALVES
(a) Using SST, push in a new oil seal.
SST 09236−00101 (09236 −15010)
HINT:
Different oil seals are used for the intake and exhaust.
(b) Install the valve (1), spring seat (2), valve spring (3) and spring retainer (4).
(c) Using SST, compress the valve spring and place the 2 keepers around the valve stem.
SST 09202−70020 (09202 −00010)
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ENGINE MECHANICAL CYLINDER HEAD
EM−53
1996 LAND CRUISER (RM451U)
(d) Using a plastic−faced hammer, lightly tap the valve stem
tip to ensure a proper fit.
7. INSTALL VALVE LIFTERS AND SHIMS
(a) Install the valve lifter and shim.
(b) Check that the valve lifter rotates smoothly by hand.
8. INSTALL ACCELERATOR CABLE BRACKET AND THROTTLE CABLE BRACKET
9. INSTALL 2 ENGINE WIRE CLAMP BRACKETS
10. INSTALL NO. 1 AND NO. 2 ENGINE HANGERS Torque: 41 N·m (420 kgf·cm, 30 ft·lbf)
11. INSTALL NO. 1 WATER BYPASS HOSE
12. ASSEMBLE AIR INTAKE CHAMBER AND INTAKE MANIFOLD ASSEMBLY
(a) Install 2 new gaskets and the air intake chamber with the
6 bolts and 2 nuts.
Torque: 21 N·m (210 kgf·cm, 15 ft·lbf)
(b) Connect the vacuum sensing hose to the fuel pressure regulator.
13. INSTALL AIR INTAKE CHAMBER AND INTAKE MAN- IFOLD ASSEMBLY
(a) Place a new gasket so that the rear mark is toward the rear side.
(b) Install the intake manifold with the 10 bolts and 2 nuts.
Torque: 21 N·m (210 kgf·cm, 15 ft·lbf)
(c) Connect the 2 vacuum hoses to the TVV.
14. INSTALL HEATER INLET PIPE AND HOSE
Install the heater hose to the cylinder head, and connect the
pipe to the intake manifold with the 2 bolts. Torque: 21 N·m (210 kgf·cm, 15 ft·lbf)
15. INSTALL EGR PIPE
(a) Temporarily install the union nut to the EGR valve.
(b) Install a new gasket and the EGR pipe to the cylinder head with the 2 bolts.
Torque: 21 N·m (210 kgf·cm, 15 ft·lbf)
(c) Tighten the union nut. Torque: 78 N·m (800 kgf·cm, 58 ft·lbf)
16. INSTALL WATER OUTLET
Install a new gasket and the water outlet with the 2 nuts. Torque: 21 N·m (210 kgf·cm, 15 ft·lbf)
17. INSTALL GENERATOR BRACKET
Install the generator bracket with the 2 bolts. Torque: 43 N·m (440 kgf·cm, 32 ft·lbf)
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EM1E7−01
EM−54
−
ENGINE MECHANICAL CYLINDER HEAD
1996 LAND CRUISER (RM451U)
INSTALLATION
1. INSTALL CYLINDER HEAD AND INTAKE MANIFOLD ASSEMBLY
(a) Place the cylinder head on the cylinder head. (1) Apply seal packing to the 2 locations as shown.
Seal packing: Part No. 08826−00080 or equivalent
NOTICE:
Do not apply too much seal packing
(2) Place a new cylinder head gasket in position on the
cylinder block.
NOTICE:
Be careful of the installation direction. (3) Place the cylinder head in position on the cylinderhead gasket.
(b) Install the cylinder head bolts.
HINT:
The cylinder head bolts are tightened in 3 progressive
steps (steps (b), (d) and (e)).
If any cylinder head bolt is broken or deformed, replace
it.
(1) Apply a light coat of engine oil on the threads and under the heads of the cylinder head bolts.
(2) Install and uniformly tighten the 14 cylinder head
bolts and plate washers in several passes, in the se-
quence shown.
Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)
If any of the cylinder head bolts does not meet the torque speci-
fication, replace the cylinder head bolt.
(3) Mark the front of the cylinder head bolt head withpaint.
(4) Retighten the cylinder head bolts by 90 ° in the nu-
merical order shown.
(5) Retighten the cylinder head bolts by an additional 90°.
(6) Check that the painted mark is now facing rearward.
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ENGINE MECHANICAL CYLINDER HEAD
EM−55
1996 LAND CRUISER (RM451U)
(7) Install and torque the 2 mounting bolts.
Torque: 21N·m (210 kgf·cm, 15 ft·lbf)
2. ASSEMBLE EXHAUST CAMSHAFT
(a) Mount the hexagon wrench head portion of the camshaft in a vise.
NOTICE:
Be careful not to damage the camshaft.
(b) Install the camshaft gear spring (1), camshaft sub −gear
(2) and wave washer (3).
HINT:
Align the pins on the gears with the spring ends.
(c) Using snap ring pliers, install the snap ring.
(d) Insert a service bolt (A) into the service hole of the cam- shaft sub−gear.
(e) Using a screwdriver, align the holes of the camshaft main
gear and sub− gear by turning camshaft sub − gear clock-
wise, and install a service bolt (B).
NOTICE:
Be careful not to damage the camshaft.
3. INSTALL CAMSHAFTS
NOTICE:
Since the thrust clearance of the camshaft is small, the
camshaft must be kept level while it is being installed. If the
camshaft is not kept level, the portion of the cylinder head
receiving the shaft thrust may crack or be damaged, caus-
ing the camshaft to seize or break. To avoid this, the follow-
ing steps should be carried out.
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