engine TOYOTA LAND CRUISER 1996 J80 Workshop Manual

P04628
EM−90
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ENGINE MECHANICAL CYLINDER BLOCK
1996 LAND CRUISER (RM451U)
19. REMOVE CHECK VALVES AND OIL NOZZLES
Remove the 6 check valves and oil nozzles.
20. REMOVE CYLINDER BLOCK ORIFICE
21. 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.
22. REMOVE PISTON RINGS
(a) Using a piston ring expander, remove the 2 compression
rings.
(b) Remove the 2 side rails and oil ring by hand.
HINT:
Arrange the rings in correct order only.
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P03870
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ENGINE MECHANICAL CYLINDER BLOCK
EM−91
1996 LAND CRUISER (RM451U)
23. DISCONNECT CONNECTING ROD FROM PISTON
(a) Using a small screwdriver, pry out the 2 snap rings.
(b) Gradually heat the piston to 80 − 90°C (176 − 194° F).
(c) Using plastic −faced hammer and brass bar, lightly tap out
the piston pin and remove the connecting rod.
HINT:
The piston and pin are a matched set.
Arrange the pistons, pins, rings, connecting rods and
bearings in correct order.
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EM1EH−02
EM−92
−
ENGINE MECHANICAL CYLINDER BLOCK
1996 LAND CRUISER (RM451U)
INSPECTION
1. CLEAN CYLINDER BLOCK
(a) Using a gasket scraper, remove all the gasket material from the top surface of the cylinder block.
(b) Using a soft brush and solvent, thoroughly clean the cylin-
der block.
2. INSPECT CYLINDER BLOCK
(a) Inspect for flatness. Using a precision straight edge and feeler gauge, mea-
sure the surfaces contacting the cylinder head gasket for
warpage.
Maximum warpage: 0.05 mm (0.0020 in.)
If warpage is greater than maximum, replace the cylinder block.
(b) Visually check the cylinder for vertical scratches.
If deep scratches are present, rebore all the 6 cylinders. If nec-
essary, replace the cylinder block.
(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.
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ENGINE MECHANICAL CYLINDER BLOCK
EM−93
1996 LAND CRUISER (RM451U)
Using a cylinder gauge, measure the cylinder bore diame-
ter at positions A, B and C in the thrust and axial direc-
tions.
Standard diameter:
STD
Mark ”1”100.000 − 100.010 mm (3.9370 − 3.9374 in.)
Mark ”2”100.010 − 100.020 mm (3.9374 − 3.9378 in.)
Mark ”3”100.020 − 100.030 mm (3.9378 − 3.9382 in.)
Maximum diameter:
STD100.23 mm (3.9461 in.)
O/S 0.50100.73 mm (3.9658 in.)
O/S 1.00101.23 mm (3.9854 in.)
If the diameter is greater than maximum, rebore all the 6 cylin-
ders. If necessary, replace the cylinder block.
(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.
(e) Inspect the main bearing cap bolts.
Using vernier calipers, measure the thread outside diam-
eter of the bolt.
Standard outside diameter:
10.85 − 11.00 mm (0.4271 − 0.4331 in.)
Minimum outside diameter: 10.6 mm (0.417 in.)
If the diameter is less than minimum, replace the bolt.
(f) Inspect the cylinder blockl oil orifice for clogging.
If necessary, replace the orifice.
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EM−94
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ENGINE MECHANICAL CYLINDER BLOCK
1996 LAND CRUISER (RM451U)
3. INSPECT BEARING OF OIL PUMP DRIVE SHAFT
GEAR
Check the bearing for pitting and scratches.
If the bearing is damaged, replace the cylinder block.
4. CLEAN PISTON
(a) Using a gasket scraper, remove the carbon from the pis-
ton top.
(b) Using a groove cleaning tool or broken ring, clean the pis-
ton ring grooves.
(c) Using solvent and a brush, thoroughly clean the piston.
NOTICE:
Do not use a wire brush.
5. 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”. The mark is stamped on the piston top.
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ENGINE MECHANICAL CYLINDER BLOCK
EM−95
1996 LAND CRUISER (RM451U)
(1) Using a micrometer, measure the piston diameter at
right angles to the piston pin center line, 42 mm
(1.65 in.) from the piston head.
Piston diameter:
STD Mark ”1”
Mark ”2”
Mark ”3”99.950 − 99.960 mm (3.9350 − 3.9354 in.)
99.960 − 99.970 mm (3.9354 − 3.9358 in.)
99.970 − 99.980 mm (3.9358 − 3.9362 in.)
O/S 0.50100.450 − 100.480 mm (3.9547 − 3.9559 in.)
O/S 1.00100.950 − 100.980 mm (3.9744 − 3.9756 in.)
(2) Measure the cylinder bore diameter in the thrust
directions (See step 2).
(3) Subtract the piston diameter measurement from the
cylinder bore diameter measurement.
Standard oil clearance:
0.040 − 0.060 mm (0.0016 − 0.0024 in.)
Maximum oil clearance: 0.080 mm (0.0031 in.)
If the oil clearance is greater than maximum, replace all the 6
pistons and rebore all the 6 cylinders. If necessary, replace the
cylinder block.
HINT:
Use new cylinder block:
Use a piston with the same number mark as the cylinder bore
diameter marked on the cylinder block.
(b) Inspect the piston ting groove clearance. Using a feeler gauge, measure the clearance between
new piston ring and the wall of the piston ring groove.
Ring groove clearance:
No. 10.040 − 0.080 (0.0016 − 0.0031 in.)
No. 20.030 − 0.070 (0.0012 − 0.0028 in.)
If the clearance is greater than maximum, replace the piston.
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P04002
125 mm
EM7639
P03829
EM−96
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ENGINE MECHANICAL CYLINDER BLOCK
1996 LAND CRUISER (RM451U)
(c) Inspect the piston ring end gap.
(1) Insert the piston ring into the cylinder bore.
(2) Using a piston, push the piston ring a little beyondthe bottom of the ring travel, 125 mm (4.92 in.) from
the top of the cylinder block.
(3) Using a feeler gauge, measure the end gap.
Standard end gap:
No. 10.300 − 0.520 mm (0.0118 − 0.0205 in.)
No. 20.450 − 0.670 mm (0.0177 − 0.0264 in.)
Oil (Side rail)0.150 − 0.520 mm (0.0059 − 0.0205 in.)
Maximum end gap:
No. 11.12 mm (0.0441 in.)
No. 21.17 mm (0.0461 in.)
Oil (Side rail)1.12 mm (0.0441 in.)
If the end gap is greater than maximum, replace the piston ring.
If the end gap is greater than maximum, even with a new piston
ring, rebore all the 6 cylinders or replace the cylinder block.
(d) Inspect the piston pin fit.
At 80 − 90°C (176 − 194°F), you should be able to push
the piston pin into the piston pin hole with your thumb.
(e) Using a rod aligner and feeler gauge, check the connect- ing rod alignment.
(1) Check for out−of−alignment.
Maximum out−of−alignment:
0.05 mm (0.0020 in.) per 100 mm (3.94 in.)
If out− of−alignment is greater than maximum, replace the con-
necting rod assembly.
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P03828
P03868
EM0227
−
ENGINE MECHANICAL CYLINDER BLOCK
EM−97
1996 LAND CRUISER (RM451U)
(2) Check for twist
Maximum twist:
0.15 mm (0.0059 in. ) per 100 mm (3.94 in.)
If twist is greater than maximum, replace the connecting rod as-
sembly.
(f) Inspect the piston pin oil clearance. (1) Using a caliper gauge, measure the inside diameter
of the connecting rod bushing.
Bushing inside diameter:
26.008 − 26.020 mm (1.0239 − 1.0244 in.)
(2) Using a micrometer, measure the piston pin diame-
ter.
Piston pin diameter:
26.000 − 26.012 mm (1.0236 − 1.0241 in.)
(3) Subtract the piston pin diameter measurement from
the bushing inside diameter measurement.
Standard oil clearance:
0.004 − 0.012 mm (0.0002 − 0.0005 in.)
Maximum oil clearance: 0.05 mm (0.0020 in.)
If the oil clearance is greater than maximum, replace the bush-
ing. If necessary, replace the piston and piston pin as a set (See
page EM−99 ).
(g) Inspect the connecting rod bolts. Install the cap nut to the connecting rod bolt. Check that
the cap nut can be turned easily by hand to the end of the
thread.
If the cap nut cannot be turned easily, measure the outside di-
ameter of the connecting rod bolt with vernier calipers. Standard outside diameter:
8.40 − 8.60 mm (0.3307 − 0.3386 in.)
Minimum outside diameter: 8.00 mm (0.3150 in.)
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EM−98
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ENGINE MECHANICAL CYLINDER BLOCK
1996 LAND CRUISER (RM451U)
HINT:
If the location of this area cannot be judged by visual inspection,
measure the outer diameter at the location shown in the illustra-
tion.
If the outside diameter is less than minimum, replace the con-
necting rod bolt and nut as a set.
6. INSPECT CRANKSHAFT
(a) Inspect for circle runout. (1) Place the crankshaft on V−blocks.
(2) Using a dial indicator, measure the circle runout atthe center journal.
Maximum circle runout: 0.06 mm (0.0024 in.)
If the circle runout is greater than maximum, replace the crank-
shaft.
(b) Inspect the main journals and crank pins. (1) Using a micrometer, measure the diameter of each
main journal and crank pin.
Main journal diameter:
STD68.982 − 69.000 mm (2.7158 − 2.7165 in.)
U/S 0.2568.745 − 68.755 mm (2.7065 − 2.7069 in.)
Crank pin diameter:
STD56.982 − 57.000 mm (2.2434 − 2.2441 in.)
U/S 0.2556.745 − 56.755 mm (2.2341 − 2.2344 in.)
If the diameter is not as specified, check the oil clearance (See
page EM−83 ). If necessary, grind or 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 maximum, replace
the crankshaft.
7. IF NECESSARY, GRIND AND HONE MAIN JOURNALS
AND/OR CRANK PINS
Grind and hone the main journals and/or crank pins to the fin-
ished undersized diameter. Install new main journal and/or
crankshaft pin undersized bearings.
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EM1EI−02
P03827
P03867
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ENGINE MECHANICAL CYLINDER BLOCK
EM−99
1996 LAND CRUISER (RM451U)
REPLACEMENT
1. REPLACE CONNECTING ROD BUSHING
(a) Using SST and a press, press out the bushing.
SST 09950 −60010 (09951 −00280), 09950 −70010
(09951 −07100)
(b) Align the oil holes of a new bushing and the connecting rod.
(c) Using SST and a press, press in the bushing. SST 09950 −60010 (09951 −00280), 09950 −70010
(09951 −07100)
(d) Using a pin hole grinder, hone the bushing to obtain the standard specified cliarance (See page EM−92) between
the bushing and piston pin.
(e) Check the piston pin fit at normal room temperature. Coat
the piston pin with engine oil, and push it into the connect-
ing rod with your thumb.
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