engine TOYOTA LAND CRUISER 1996 J80 Workshop Manual
[x] Cancel search | Manufacturer: TOYOTA, Model Year: 1996, Model line: LAND CRUISER, Model: TOYOTA LAND CRUISER 1996 J80Pages: 1399, PDF Size: 41.35 MB
Page 885 of 1399
P04907
P08469
SST
EM−100
−
ENGINE MECHANICAL CYLINDER BLOCK
1996 LAND CRUISER (RM451U)
2. REPLACE OVERSIZED (O/S) PISTONS FOR CYLIN-
DER BORING
HINT:
Bore all the 6 cylinders for the O/S piston outside diame-
ter.
Replace all the piston rings with ones to match the O/S
pistons.
(a) Keep 6 new O/S pistons. O/S piston diameter:
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.)
(b) 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.
(c) Calculate the amount of each cylinder is to be rebored as
follows:
Size to be rebored = P + C − H
P = Piston diameter
C = Piston oil clearance
0.040 − 0.060 mm (0.0016 − 0.0024 in.)
H = Allowance for honing
0.02 mm (0.0008 in.) or less
(d) Bore and hone the cylinders to calculated dimensions. Maximum honing: 0.02 mm (0.0008 in.)
NOTICE:
Excess honing will destroy the finished roundness.
3. REPLACE CRANKSHAFT FRONT OIL SEAL
HINT:
There are 2 methods ((a) and (b)) to replace the oil seal.
(a) If the timing chain cover is removed from the cylinder block:
(1) Using a screwdriver and a hammer, tap out the oilseal.
(2) Using SST and a hammer, tap in a new oil seal until
its surface is flush with the timing chain cover edge.
SST 09316−60011 (09316 −00011, 09316−00051)
(3) Apply MP grease to the oil seal lip.
NOTICE:
Do not let foreign matter get onto the lip of the oil seal.
Brought to you by BirfMark
Brought to you by BirfMark
Version 1.11 - 03/16/2010
Page 886 of 1399
P05005
P08506
SST
P04518
P04970
SST
P08643
Cut Position
−
ENGINE MECHANICAL CYLINDER BLOCK
EM−101
1996 LAND CRUISER (RM451U)
(b) If the timing chain cover is installed to the cylinder block:
(1) Using a screwdriver, pry out the oil seal.
NOTICE:
Be careful not to damage the crankshaft. Tape the screw-
driver tip.
(2) Apply MP grease to a new oil seal lip.
NOTICE:
Do not let foreign matter get onto the lip of the oil seal.
(3) Using SST and a hammer, tap in the oil seal until its
surface is flush with the timing chain cover edge.
SST 09316−60011 (09316 −00011, 09316−00051)
4. REPLACE CRANKSHAFT REAR OIL SEAL
HINT:
There are 2 methods ((a) and (b)) to replace the oil seal.
(a) If the rear oil seal retainer is removed from the cylinder block:
(1) Using a screwdriver and a hammer, tap out the oil
seal.
(2) Using SST and a hammer, tap in a new oil seal until
its surface is flush with the rear oil seal edge.
SST 09223−15030, 09950 −70010 (09951−07150)
NOTICE:
Do not let foreign matter get onto the lip of the oil seal.
(b) If the rear oil seal retainer is installed to the cylinder block:
(1) Using a knife, cut off the oil seal lip.
(2) Using a screwdriver, pry out the oil seal.
NOTICE:
Be careful not to damage the crankshaft. Tape the screw-
driver tip.
Brought to you by BirfMark
Brought to you by BirfMark
Version 1.11 - 03/16/2010
Page 887 of 1399
P23172
CORRECTWRONG
EM−102
−
ENGINE MECHANICAL CYLINDER BLOCK
1996 LAND CRUISER (RM451U)
(3) Using SST and a hammer, tap in a new oil seal until
its surface is flush with the rear oil seal retainer
edge.
SST 09223−15030, 09950 −70010 (09951−07150)
NOTICE:
Do not let foreign matter get onto the lip of the oil seal. (4) Check that the lip of the oil seal is not bent inward.
Brought to you by BirfMark
Brought to you by BirfMark
Version 1.11 - 03/16/2010
Page 888 of 1399
EM1EJ−01
P04409
−
ENGINE MECHANICAL CYLINDER BLOCK
EM−103
1996 LAND CRUISER (RM451U)
REASSEMBLY
HINT:
Thoroughly clean all parts to be assembled.
Before installing the parts, apply new engine oil to all sli-
dining and rotating surfaces.
Replace all gaskets, O−rings and oil seals with new parts.
1. ASSEMBLE PISTON AND CONNECTING ROD
(a) Install a new snap ring on one side of the piston pin hole.
(b) Gradually heat the piston to 80 − 90° C (176 − 194°F).
(c) Coat the piston pin with engine oil.
(d) Align the front marks of the piston and connecting rod, and push in the piston pin with your thumb.
(e) Install a new snap ring on the other side of the piston pin hole.
2. INSTALL PISTON RINGS
(a) Install the oil ring expander and 2 side rails by hand.
(b) Using a piston ring expander, install the 2 compression rings with the code mark facing upward.
Code mark:
No. 11R
No. 22R
Brought to you by BirfMark
Brought to you by BirfMark
Version 1.11 - 03/16/2010
Page 889 of 1399
EM−104
−
ENGINE MECHANICAL CYLINDER BLOCK
1996 LAND CRUISER (RM451U)
(c) Position the piston rings so that the ring ends are as shown.
NOTICE:
Do not align the ring ends.
3. INSTALL BEARINGS
(a) Align the bearing claw with the groove of the connecting
rod or connecting rod cap.
(b) Install the bearings in the connecting rod and connecting rod cap.
4. INSTALL CYLINDER BLOCK ORIFICE
5. INSTALL OIL NOZZLES AND CHECK VALVES
(a) Align the pin of the oil nozzle with the pin hole of the cylin-
der block.
(b) Install the oil nozzle with the check valve. Install the 6 oil nozzles and check valves.
Torque: 25 N·m (250 kgf·cm, 18 ft·lbf)
Brought to you by BirfMark
Brought to you by BirfMark
Version 1.11 - 03/16/2010
Page 890 of 1399
P03813
P05520A16079
−
ENGINE MECHANICAL CYLINDER BLOCK
EM−105
1996 LAND CRUISER (RM451U)
6. INSTALL MAIN BEARINGS
(a) Align the bearing claw with the claw groove of the cylinder
block, and push in the 7 upper bearings.
(b) Align the bearing claw with the claw groove of the main bearing cap, and push in the 7 lower bearings.
HINT:
A number is marked on each main bearing cap to indicate the
installation position.
7. INSTALL UPPER THRUST WASHERS
Install the 2 thrust washers under the No.4 journal position of
the cylinder block with the oil grooves facing outward.
8. PLACE CRANKSHAFT ON CYLINDER BLOCK
9. INSTALL MAIN BEARING CAPS AND LOWER THRUST WASHERS
(a) Place the main bearing caps and lower thrust washers on
the cylinder block.
(1) Install the 2 thrust washers on the No.4 bearing cap
with the grooves facing outward.
Brought to you by BirfMark
Brought to you by BirfMark
Version 1.11 - 03/16/2010
Page 891 of 1399
EM−106
−
ENGINE MECHANICAL CYLINDER BLOCK
1996 LAND CRUISER (RM451U)
(2) Install the 7 main bearing caps in their proper loca-
tions.
HINT:
Each bearing cap has a number and front mark.
(b) Install the main bearing cap bolts.
HINT:
The main bearing cap bolts are tightened in 2 progressive
steps (steps (b) and (d)).
If any of the main bearing cap bolts is broken or deformed,
replace it.
(1) Apply a light coat of engine oil on the threads and
under the heads of the main bearings cap bolts.
(2) Install and uniformly tighten the 14 bolts of the main
bearing caps, in several passes, in the sequence
shown.
Torque: 74 N·m (750 kgf·cm, 54 ft·lbf)
If any one of the main bearing cap bolts does not meet the
torque specification, replace the main bearing cap bolt.
(3) Mark the front of the main bearing cap bolt withpaint.
(4) Retighten the main bearing cap bolts by 90 ° in the
numerical order shown above.
(5) Check that the painted mark is now at a 90° angle
to the front.
(c) Check that the crankshaft turns smoothly.
(d) Check that the crankshaft thrust clearance (See page EM−83 ).
10. INSTALL PISTON AND CONNECTING ROD AS- SEMBLIES
(a) Cover the connecting rod bolts with a short piece of hose
to protect the crankshaft from damage.
Brought to you by BirfMark
Brought to you by BirfMark
Version 1.11 - 03/16/2010
Page 892 of 1399
−
ENGINE MECHANICAL CYLINDER BLOCK
EM−107
1996 LAND CRUISER (RM451U)
(b) Using a piston ring compressor, push the correctly num-
bered piston and connecting rod assemblies into each
cylinder with the front mark of the piston facing forward.
11. INSTALL CONNECTING ROD CAP
(a) Place the connecting rod cap on the connecting rod. (1) Match the numbered connecting rod cap with theconnecting rod.
(2) Install the connecting rod cap with the front mark facing for ward.
(b) Install the connecting rod cap nuts.
HINT:
The connecting rod cap nuts are tightened in 2 progres-
sive steps (steps (b) and (d)).
If any connecting rod bolt is broken or deformed, replace
it.
(1) Apply a light coat of engine oil on the threads and under the nuts of the connecting rod cap.
(2) Install and alternately tighten the nuts of the con-
necting rod cap in several passes.
Torque: 48 N·m (490 kgf·cm, 35 ft·lbf)
If any one of the connecting rod cap nuts does not meet the
torque specification, replace the connecting rod bolt and cap
nut as a set.
(3) Mark the front of the connecting rod cap nut and bolt
with paint.
(4) Retighten the connecting rod cap nuts 90 ° as
shown.
Brought to you by BirfMark
Brought to you by BirfMark
Version 1.11 - 03/16/2010
Page 893 of 1399
P04615
EM−108
−
ENGINE MECHANICAL CYLINDER BLOCK
1996 LAND CRUISER (RM451U)
(5) Check that the painted mark on the nut is at 90 °
angle in relation to the mark on the bolt.
(c) Check that the crankshaft turns smoothly.
(d) Check that the connecting rod thrust clearance (See page
EM−83 ).
12. INSTALL REAR OIL SEAL RETAINER
(a) Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the retainer
and cylinder block.
Using a razor blade and gasket scraper, remove all
the old packing (FIPG) material from the gasket sur-
faces and sealing groove.
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 retainer as shown in the illustra-
tion.
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) Install the retainer with the 4 bolts. Torque: 21 N·m (210 kgf·cm, 15 ft·lbf)
13. INSTALL OIL COOLER COVER AND OIL COOLER
Install a new gasket, the oil cooler cover and oil cooler with the
10 bolts and 2 nuts. Torque: 21 N·m (210 kgf·cm, 15 ft·lbf)
Brought to you by BirfMark
Brought to you by BirfMark
Version 1.11 - 03/16/2010
Page 894 of 1399
−
ENGINE MECHANICAL CYLINDER BLOCK
EM−109
1996 LAND CRUISER (RM451U)
14. INSTALL LH ENGINE MOUNTING BRACKET
(a) Install the bracket with the 4 bolts.
Torque: 69 N·m (700 kgf·cm, 51 ft·lbf)
(b) Install the insulator with the nut. Torque: 72 N·m (730 kgf·cm, 43 ft·lbf)
15. INSTALL RH ENGINE MOUNTING BRACKET
(a) Install the bracket with the 4 bolts. Torque: 69 N·m (700 kgf·cm, 51 ft·lbf)
(b) Install the insulator with the nut. Torque: 72 N·m (730 kgf·cm, 43 ft·lbf)
16. INSTALL PS PUMP
(a) Place a new O−ring to the pump.
(b) Install the pump with the 2 nuts.
Torque: 36 N·m (370 kgf·cm, 27 ft·lbf)
17. INSTALL KNOCK SENSORS
Using SST, install the 2 knock sensors. SST 09816−30010
Torque: 44 N·m (450 kgf·cm, 33 ft·lbf)
18. INSTALL OIL FILTER UNION
Torque: 44 N·m (450 kgf·cm, 33 ft·lbf)
19. INSTALL OIL FILTER (See page LU−2)
20. INSTALL TIMING CHAIN (See page EM−19)
21. INSTALL CYLINDER HEAD (See page EM−54 )
22. REMOVE ENGINE STAND
23. INSTALL DRIVE PLATE
(a) Install the front spacer, drive plate and rear plate on the crankshaft.
(b) Install and uniformly tighten the 10 drive plate bolts, in several passes, in the sequence shown.
Torque: 100 N·m (1,000 kgf·cm, 74 ft·lbf)
Brought to you by BirfMark
Brought to you by BirfMark
Version 1.11 - 03/16/2010