Timing TOYOTA LAND CRUISER 1996 J80 Owner's Manual

EM1E9−01
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ENGINE MECHANICAL TIMING CHAIN
EM−13
1996 LAND CRUISER (RM451U)
REMOVAL
1. DRAIN ENGINE OIL
2. DRAIN ENGINE COOLANT
3. REMOVE ENGINE UNDER COVER
4. REMOVE RADIATOR (See page CO−14 )
5. DISCONNECT A/C COMPRESSOR AND BRACKET
(a) Loosen the idler pulley nut and adjusting bolt, and remove
the drive belt.
(b) Remove the 4 mounting bolts, and disconnect the com- pressor from the bracket.
HINT:
Put aside the compressor, and suspend it.
(c) Remove the 5 bolts and A/C compressor bracket.
6. REMOVE RADIATOR PIPE
(a) Disconnect the No. 2 radiator hose from the water inlet.
(b) Remove the 2 nuts and radiator pipe.
7. REMOVE WATER PUMP
Remove the 4 bolts, 2 nuts, water pump and gasket.
8. REMOVE CYLINDER HEAD (See page EM−28 )
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EM−14
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ENGINE MECHANICAL TIMING CHAIN
1996 LAND CRUISER (RM451U)
9. DISCONNECT OIL COOLER PIPE BRACKET FROM
NO. 1 OIL PAN
10. REMOVE OIL LEVEL SENSOR
(a) Remove the 4 bolts and level sensor.
(b) Remove the gasket from the level sensor.
11. REMOVE BOLTS HOLDING NO.1 OIL PAN TO TRANS-
MISSION HOUSING
Remove the 6 bolts.
12. REMOVE NO. 2 OIL PAN (See page LU−5)
13. REMOVE NO. 1 OIL PAN (See page LU−5)
14. REMOVE CRANKSHAFT PULLEY
(a) Using SST, remove the pulley bolt. SST 09213−58012, 09330 −00021
(b) Remove the crankshaft pulley.
HINT:
If necessary, remove the pulley with SST. SST 09950−50010 (09951 −05010, 09952−05010,
09953 −05010, 09953 −05020, 09954−05020)
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ENGINE MECHANICAL TIMING CHAIN
EM−15
1996 LAND CRUISER (RM451U)
15. CHECK THRUST CLEARANCE OF OIL PUMP DRIVE
SHAFT GEAR
Using a dial indicator with lever type attachment, measure the
thrust clearance.
Standard thrust clearance:
0.040 − 0.160 mm (0.0016 − 0.0063 in.)
Maximum thrust clearance: 0.30 mm (0.0118 in.)
If the thrust clearance is greater than maximum, replace the oil
pump drive shaft gear and/or timing chain cover.
16. REMOVE DRIVE BELT IDLER PULLEY
Remove the bolt and idler pulley.
17. REMOVE TIMING CHAIN COVER
(a) Remove the 9 mounting bolts, 2 mounting nuts and drive belt adjusting bar.
(b) Remove the oil pump by prying the portions between the cylinder block and oil pump with a screwdriver.
NOTICE:
Be careful not to damage the contact surfaces of the cylin-
der block and oil pump.
(c) Remove the O−rings from the oil pump.
(d) Remove the gasket from the oil pump.
18. REMOVE TIMING CHAIN AND CAMSHAFT TIMING GEAR
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EM−16
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ENGINE MECHANICAL TIMING CHAIN
1996 LAND CRUISER (RM451U)
19. REMOVE CRANKSHAFT TIMING GEAR
HINT:
If necessary, remove the gear with SST.
SST 09950−40010 (09951 −04010, 09952−04010,
09953 −04020, 09954 −04010, 09955 −04060),
09950 −60010 (09951 −00350)
20. REMOVE CHAIN TENSIONER SLIPPER AND VIBRA- TION DAMPER
(a) Using a 10 mm hexagon wrench, remove the bolt and slip-
per.
(b) Remove the 2 bolts and damper.
21. REMOVE OIL JET
Remove the bolt and oil jet.
22. REMOVE CRANKSHAFT ROTOR
23. REMOVE OIL PUMP DRIVE SHAFT GEAR
24. REMOVE PUMP DRIVE SHAFT GEAR
If the pump drive shaft gear cannot be removed by hand, use
2 screwdrivers.
NOTICE:
Position shop rags as shown to prevent damage.
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P04776
146.6 mm16 Links
EM1EA−01
P03876
−
ENGINE MECHANICAL TIMING CHAIN
EM−17
1996 LAND CRUISER (RM451U)
INSPECTION
1. INSPECT TIMING CHAIN AND TIMING GEARS
(a) Measure the length of 16 links with the chain fully
stretched.
Maximum chain elongation: 146.6 mm (5.772 in.)
If the elongation is greater than maximum, replace the chain.
HINT:
Make the same measurements pulling at 3 or more places se-
lected at random.
(b) Wrap the chain around the timing gear.
(c) Using vernier calipers, measure the timing gear diameter with the chain.
NOTICE:
Vernier calipers must contact the chain rollers for measur-
ing.
Minimum gear diameter (w/Chain):
Camshaft126.0 mm (4.961 in.)
Crankshaft65.4 mm (2.575 in.)
If the diameter is less than minimum, replace the chain and
gears.
2. INSPECT CHAIN TENSIONER SLIPPER AND VIBRA-TION DAMPER
Measure the chain tensioner slipper and vibration damper
wears. Maximum wear: 1.0 mm (0.039 in.)
If the wear is greater than maximum, replace the slipper and/or
damper.
3. INSPECT OIL JET
Check the oil jet for damage or clogging.
If necessary, replace the oil jet.
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EM1Q5−01
EM−18
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ENGINE MECHANICAL TIMING CHAIN
1996 LAND CRUISER (RM451U)
REPLACEMENT
REPLACE CRANKSHAFT FRONT OIL SEAL (See page EM−99)
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EM1EB−01
−
ENGINE MECHANICAL TIMING CHAIN
EM−19
1996 LAND CRUISER (RM451U)
INSTALLATION
1. SET CRANKSHAFT
Turn the crankshaft until the set key on crankshaft facing down-
ward.
2. INSTALL PUMP DRIVE SHAFT GEAR
3. INSTALL OIL PUMP DRIVE SHAFT GEAR
(a) Apply a light coat of engine oil on the shaft portion of the
gear.
(b) Install the gear.
4. INSTALL CRANKSHAFT ROTOR
5. INSTALL OIL JET
Install the oil jet with the bolt. Torque: 20 N·m (200 kgf·cm, 14 ft·lbf)
6. INSTALL CHAIN TENSIONER SLIPPER AND VIBRA- TION DAMPER
(a) Install the damper with the 2 bolts.
Torque: 20 N·m (200 kgf·cm, 14 ft·lbf)
(b) Using a 10 mm hexagon wrench, install the slipper with the bolt.
Torque: 69 N·m (700 kgf·cm, 51 ft·lbf)
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EM−20
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ENGINE MECHANICAL TIMING CHAIN
1996 LAND CRUISER (RM451U)
(c) Check that the slipper moves smoothly.
7. INSTALL CRANKSHAFT TIMING GEAR
NOTICE:
Be careful of the installation direction.
HINT:
If necessary, install the gear with SST.
SST 09636−20010
8. INSTALL TIMING CHAIN AND CAMSHAFT TIMING GEAR
(a) Install the timing chain on the camshaft timing gear with the bright link aligned with the timing mark on the cam-
shaft timing gear.
(b) Install the timing chain on the crankshaft timing gear with the other bright link aligned with the timing mark on the
crankshaft timing gear.
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−
ENGINE MECHANICAL TIMING CHAIN
EM−21
1996 LAND CRUISER (RM451U)
(c) Tie the timing chain with a cord as shown in the illustration
and make sure it doesn’t come loose.
9. INSTALL TIMING CHAIN COVER
(a) Remove any old packing (FIPG) material and be careful
not to drop any oil on the contact surfaces of the timing
chain cover and cylinder block.
Using a razor blade and gasket scraper, remove all
the old packing (FIPG) material from the gasket sur-
faces and sealing grooves.
Thoroughly clean all components to remove all the
loose material.
Using a non −residue solvent, clean both sealing
surfaces.
(b) Apply seal packing to the timing chain cover as shown in the illustration.
Seal packing: Part No. 08826−00080 or equivalent
Install a nozzle that has been cut to a 2 − 3 mm (0.08
− 0.12 in.) opening.
HINT:
Avoid applying an excessive amount to the surface.
Parts must be assembled within 5 minutes of ap-
plication. Otherwise the material must be removed
and reapplied.
Immediately remove nozzle from the tube and rein-
stall cap.
(c) Place 2 new O− rings in position on the timing chain cover.
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EM−22
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ENGINE MECHANICAL TIMING CHAIN
1996 LAND CRUISER (RM451U)
(d) Engage the gear of the oil pump drive rotor with the gear
of the oil pump drive gear, and install the oil pump.
(e) Install the oil pump and drive belt adjusting bar with the 9 bolts and 2 nuts.
Torque: 21 N·m (210 kgf·cm, 15 ft·lbf)
HINT:
Each bolt length is indicated in the illustration.
Bolt A: 30 mm (1.18 in.)
Bolt B: 50 mm (1.97 in.)
Bolt C: 60 mm (2.38 in.)
(f) Remove the cord from the chain.
10. INSTALL DRIVE BELT IDLER PULLEY
Install the pulley with the bolt. Torque: 43 N·m (440 kgf·cm, 32 ft·lbf)
11. INSTALL CRANKSHAFT PULLEY
(a) Align the pulley set key with the key groove of the pulley, and slide on the pulley.
(b) Using SST, install and torque the pulley bolt.
SST 09213−58012, 09330 −00021
Torque: 412 N·m (4,200 kgf·cm, 304 ft·lbf)
12. INSTALL NO. 1 OIL PAN (See page LU−12)
13. INSTALL NO. 2 OIL PAN (See page LU−12)
14. INSTALL BOLTS HOLDING NO. 1 OIL PAN TO TRANS-
MISSION HOUSING
Install the 6 bolts. Torque: 72 N·m (730 kgf·cm, 53 ft·lbf)
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