engine TOYOTA LAND CRUISER 1996 J80 Workshop Manual

EM−30
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ENGINE MECHANICAL CYLINDER HEAD
1996 LAND CRUISER (RM451U)
(b) Disconnect the connectors.
(1) Disconnect the knock sensor connector.
(2) Disconnect the oil level sensor connector.
(3) Disconnect the 2 connectors from the transmission.
(4) Disconnect the starter connector.
(c) Disconnect the 2 heated oxygen sensor connectors.
(d) Disconnect the PNP switch connector.
(e) Remove the 2 bolts and disconnect the engine wire from the intake manifold and cylinder block.
(f) Disconnect the PCV hose from the PCV valve.
(g) Remove the bolt holding the engine wire to the intake manifold.
(h) Disconnect the connectors. (1) Disconnect the connector for the emission controlvalve set assembly.
(2) Disconnect the 3 injector connectors.
(i) Disconnect the engine wire clamp.
(j) Disconnect the engine wire clamp.
(k) Disconnect the connectors.
(1) Disconnect the 3 injector connectors.
(2) Disconnect the EGR gas temp. sensor connector.
(l) Disconnect the clamp of the No. 6 injector wire from the bracket.
(m) Disconnect the engine wire from the cylinder head and in-
take manifold.
25. DISCONNECT NO. 2 WATER BYPASS PIPE
Remove the 3 bolts, and disconnect the bypass pipe from the
cylinder head.
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ENGINE MECHANICAL CYLINDER HEAD
EM−31
1996 LAND CRUISER (RM451U)
26. REMOVE FRONT EXHAUST PIPE
(a) Disconnect the heated oxygen sensor connector.
(b) Remove the 2 nuts and 2 bolts holding the front exhaust
pipe to the rear TWC.
(c) Disconnect the front exhaust pipe, and remove the gas- ket.
(d) Loosen the clamp bolt and disconnect the clamp from the
No. 1 support bracket.
(e) Remove the 2 bolts and No. 1 support bracket.
(f) Remove the 4 nuts, front exhaust pipe and 2 gaskets.
27. REMOVE NO. 1 AND NO. 2 EXHAUST MANIFOLDS
(a) Remove the 6 bolts, No. 1 heat insulator and No. 2 heat insulator.
(b) Remove the 13 nuts, No. 1 exhaust manifold, No. 2 ex- haust manifold and 2 gaskets.
28. REMOVE HEATER PIPE
Remove the 2 bolts, 2 nuts, ground cable, heater pipe and gas-
ket.
29. REMOVE WATER BYPASS OUTLET AND PIPE
(a) Remove the 2 bolts and water bypass outlet and pipe.
(b) Remove the 3 O−rings from the water bypass outlet and pipe.
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P08374A16075
1 Dot Mark
EM−32
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ENGINE MECHANICAL CYLINDER HEAD
1996 LAND CRUISER (RM451U)
30. REMOVE CYLINDER HEAD COVER
Remove the 13 bolts, cylinder head cover and gasket.
31. REMOVE SPARK PLUGS
32. SET NO. 1 CYLINDER TO TDC/COMPRESSION
(a) Turn the crankshaft pulley and align its groove with the ”0”
mark on the timing chain cover.
(b) Check that the timing marks (1 and 2 dots) of the camshaft
drive and driven gears are in straight line on the cylinder
head surface as shown in the illustration.
If not, turn the crankshaft 1 revolution (360° ) and align the
marks as above.
33. REMOVE CHAIN TENSIONER
Remove the 2 nuts, chain tensioner and gasket.
34. REMOVE CAMSHAFT TIMING GEAR
(a) Remove the semi−circular plug.
(b) Place the matchmarks on the camshaft timing gear and timing chain.
(c) Hold the intake camshaft with a wrench, remove the bolt and distributor gear.
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P22143A16076
2 Dot Marks
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ENGINE MECHANICAL CYLINDER HEAD
EM−33
1996 LAND CRUISER (RM451U)
(d) Remove the camshaft timing gear and chain from the in-
take camshaft and leave on the slipper and damper.
35. REMOVE CAMSHAFTS
NOTICE:
Since the thrust clearance of the camshaft is small, the
camshaft must be kept level while it is being removed. 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.
(a) Remove the exhaust camshaft. (1) Bring the service bolt hole of the driven sub −gear
upward by turning the hexagon wrench head por-
tion of the exhaust camshaft with a wrench.
(2) Secure the exhaust camshaft sub −gear to the main
gear with a service bolt.
Recommended service bolt:
Thread diameter6 mm
Thread pitch1.0 mm
Bolt length16 − 20 mm (0.63 − 0.79 in.)
HINT:
When removing the camshaft, make sure that the torsional
spring force of the sub −gear has been eliminated by the above
operation.
(3) Set the timing mark (2 dot marks) of the camshaftdriven gear at approx. 35 ° angle by turning the
hexagon wrench head portion of the intake cam-
shaft with a wrench.
(4) Lightly push the camshaft towards the rear without applying excessive force.
(5) Loosen and remove the No. 1 bearing cap bolts, al-
ternately loosening the left and right bolts uniformly.
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P22567A16077
2 Dot Marks
EM−34
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ENGINE MECHANICAL CYLINDER HEAD
1996 LAND CRUISER (RM451U)
(6) Loosen and remove the No. 2, No. 3, No. 5 and No.
7 bearing cap bolts, alternately loosening the left
and right bolts uniformly in several passes, in the
sequence shown.
NOTICE:
Do not remove the No. 4 and No. 6 bearing cap bolts at this
stage. (7) Remove the 4 bearing caps.
(8) Alternately and uniformly loosen and remove theNo. 4 and No. 6 bearing cap bolts.
HINT:
As the 4 No. 4 and No. 6 bearing cap bolts are loosened,
make sure that the camshaft is lifted out straight and level.
If the camshaft is not being lifted out straight and level, re-
tighten the 4 No. 4 and No. 6 bearing cap bolts. Then re-
verse the order of above steps from (g) to (e) and repeat
steps from (c) to (h) once again.
NOTICE:
Do not pry on or attempt to force the camshaft with a tool
or other object.
(9) Remove the 2 bearing caps and exhaust camshaft.
(b) Remove the intake camshaft. (1) Set the timing mark (2 dot marks) of the camshaftdrive gear at approx. 25 ° angle by turning the hexa-
gon wrench head portion of the intake camshaft
with a wrench.
HINT:
The above angle arrows the No. 1 and No. 4 cylinder cam lobes
of the intake camshaft to push their valve lifters evenly.
(2) Lightly push the intake camshaft towards the frontwithout applying excessive force.
(3) Loosen and remove the No. 1 bearing cap bolts, al-
ternately loosening the left and right bolts uniformly.
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ENGINE MECHANICAL CYLINDER HEAD
EM−35
1996 LAND CRUISER (RM451U)
(4) Loosen and remove the No. 3, No. 4, No. 6 and No.
7 bearing cap bolts, alternately loosening the left
and right bolts uniformly in several passes, in the
sequence shown.
NOTICE:
Do not remove the No. 2 and No. 5 bearing cap bolts at this
stage. (5) Remove the 4 bearing caps.
(6) Alternately and uniformly loosen and remove theNo. 2 and No. 5 bearing cap bolts.
HINT:
As the 4 No. 2 and No. 5 bearing cap bolts are loosened,
make sure that the camshaft is lifted out straight and level.
If the camshaft is not being lifted out straight and level, re-
tighten the 4 No. 2 and No. 5 bearing cap bolts. Then re-
verse the order of above steps from (e) to (c) and repeat
steps from (a) to (f) once again.
NOTICE:
Do not pry on or attempt to force the camshaft with a tool
or other object.
(7) Remove the 2 bearing caps and exhaust camshaft.
36. DISASSEMBLE EXHAUST CAMSHAFT
(a) Mount the hexagon wrench head portion of the camshaft in a vise.
NOTICE:
Be careful not to damage the camshaft.
(b) Insert a service bolt (A) into the service hole of the cam-
shaft sub−gear.
(c) Using a screwdriver, turn the sub− gear clockwise, and re-
move the service bolt (B).
NOTICE:
Be careful not to damage the camshaft.
(d) Using snap ring pliers, remove the snap ring.
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EM−36
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ENGINE MECHANICAL CYLINDER HEAD
1996 LAND CRUISER (RM451U)
(e) Remove the wave washer (1), camshaft sub− gear (2) and
camshaft gear spring (3).
37. REMOVE CYLINDER HEAD AND INTAKE MANIFOLD ASSEMBLY
(a) Remove the 2 bolts in front of the head before the other head bolts are removed.
(b) Uniformly loosen and remove the 14 cylinder head bolts, in several passes, in the sequence shown.
NOTICE:
Cylinder head warpage or cracking could result from re-
moving bolts in incorrect order.
(c) Lift the cylinder head from the dowels on the cylinder block, and place the cylinder head on wooden blocks on
a bench.
HINT:
If the cylinder head is difficult to lift off, pry between the cylinder
head and cylinder block with a screwdriver.
NOTICE:
Be careful not to damage the contact surfaces of the cylin-
der head and cylinder block.
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EM1E4−01
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ENGINE MECHANICAL CYLINDER HEAD
EM−37
1996 LAND CRUISER (RM451U)
DISASSEMBLY
1. REMOVE GENERATOR BRACKET
Remove the 2 bolts and generator bracket.
2. REMOVE WATER OUTLET
Remove the 2 nuts, water outlet and gasket.
3. REMOVE EGR PIPE
(a) Loosen the union nut.
(b) Remove the 2 bolts, EGR pipe and gasket.
4. REMOVE HEATER INLET PIPE AND HOSE
Remove the 2 bolts, and disconnect the pipe and hose.
5. REMOVE AIR INTAKE CHAMBER AND INTAKE MAN-
IFOLD ASSEMBLY
(a) Disconnect the 2 vacuum hoses from the TVV.
(b) Remove the 10 bolts, 2 nuts, intake manifold and gasket.
6. DISASSEMBLE AIR INTAKE CHAMBER AND INTAKE MANIFOLD ASSEMBLY
(a) Disconnect the vacuum sensing hose from the fuel pres-
sure regulator.
(b) Remove the 6 bolts, 2 nuts, air intake chamber and 2 gas-
kets from the intake manifold.
7. REMOVE NO. 1 WATER BYPASS HOSE
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EM−38
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ENGINE MECHANICAL CYLINDER HEAD
1996 LAND CRUISER (RM451U)
8. REMOVE NO. 1 AND NO. 2 ENGINE HANGERS
9. REMOVE 2 ENGINE WIRE CLAMP BRACKETS
Remove the 2 bolts and 2 wire clamp brackets.
10. REMOVE ACCELERATOR CABLE BRACKET AND
THROTTLE CABLE BRACKET
Remove the 2 bolts and 2 cable brackets.
11. REMOVE VALVE LIFTERS AND SHIMS
HINT:
Arrange the valve lifters and shims in correct order.
12. REMOVE VALVES
(a) Using SST, compress the valve spring and remove the 2 keepers.
SST 09202−70020 (09202 −00010)
(b) Remove the spring retainer, valve spring and valve.
(c) Using needle −nose pliers, remove the oil seal.
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ENGINE MECHANICAL CYLINDER HEAD
EM−39
1996 LAND CRUISER (RM451U)
(d) Using compressed air and a magnetic finger, remove the
spring seat by blowing air.
HINT:
Arrange the valves, valve springs, spring seats and spring re-
tainers in correct order.
13. REMOVE ECT SENDER GAUGE
14. REMOVE ECT CUT SWITCH
15. REMOVE ECT SENSOR
16. REMOVE TVV
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