engine oil TOYOTA LAND CRUISER 1996 J80 Service Manual

P04776
146.6 mm16 Links
EM1EA−01
P03876
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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
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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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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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ENGINE MECHANICAL TIMING CHAIN
EM−23
1996 LAND CRUISER (RM451U)
15. INSTALL OIL LEVEL SENSOR
(a) Install a new gasket to the level sensor.
(b) Install the level sensor with the 4 bolts.
Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf)
16. CONNECT OIL COOLER PIPE BRACKET TO NO. 1 OIL
PA N
17. INSTALL CYLINDER HEAD (See page EM−54 )
NOTICE:
However, for the installation of the camshaft timing gear
and timing chain, follow the below procedure. Align the
blight link of the timing chain and camshaft timing gear
mark, and install them to the camshaft.
18. INSTALL WATER PUMP
Install a new gasket and water pump with the 4 bolts and 2 nuts.
Torque: 21 N·m (210 kgf·cm, 15 ft·lbf)
19. INSTALL RADIATOR PIPE
(a) Connect the No.2 radiator hose to the water inlet.
(b) Install the 2 nuts holding the radiator pipe to the No.1 oil
pan.
Torque: 21 N·m (210 kgf·cm, 15 ft·lbf)
20. INSTALL A/C COMPRESSOR AND BRACKET
(a) Install the A/C compressor bracket with the 5 bolts.
Torque: 37 N·m (375 kgf·cm, 27 ft·lbf)
(b) Install the A/C compressor with the 4 bolts. Torque: 25 N·m (250 kgf·cm, 18 ft·lbf)
(c) Install and adjust the drive belt (See page CH−2).
21. INSTALL RADIATOR (See page CO−16 )
22. FILL ENGINE WITH OIL
23. INSTALL ENGINE UNDER COVER
24. START ENGINE AND CHECK FOR LEAKS
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ENGINE MECHANICAL CYLINDER HEAD
EM−29
1996 LAND CRUISER (RM451U)
16. DISCONNECT PS RESERVOIR TANK
Remove the 3 bolts and disconnect the reservoir tank.
17. DISCONNECT RADIATOR INLET HOSE
18. DISCONNECT NO. 3 WATER BYPASS HOSE
19. REMOVE GENERATOR (See page CH−8 )
20. REMOVE THROTTLE BODY (See page SF−45)
21. REMOVE OIL DIPSTICKS AND GUIDES FOR ENGINE AND TRANSMISSION
(a) Remove the 2 mounting bolts.
(b) Pull out the dipstick together with dipstick guide.
(c) Remove the O−ring from the dipstick guide.
22. REMOVE INTAKE MANIFOLD STAY
Remove the 2 bolts and intake manifold stay.
23. DISCONNECT FUEL INLET HOSE
Remove the union bolt and 2 gaskets, and disconnect the fuel
inlet hose from the fuel filter.
24. DISCONNECT ENGINE WIRE
(a) Disconnect the connectors. (1) Disconnect the ECT sender gauge connector.
(2) Disconnect the ECT cut switch connector.
(3) Disconnect the ECT sensor connector.
(4) Disconnect the knock sensor connector.
(5) Disconnect the crankshaft position sensor connec-tor.
(6) Remove the bolt and disconnect the engine wire from the cylinder block.
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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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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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EM1Q7−01
EM−40
−
ENGINE MECHANICAL CYLINDER HEAD
1996 LAND CRUISER (RM451U)
INSPECTION
1. CLE AN TO P SURFACE S OF PIS TO NS AND CY L- INDER BLOCK
(a) Turn the crankshaft, and bring each piston to top dead center (TDC). Using a gasket scraper, remove all the car-
bon from the piston top surface.
(b) Using a gasket scraper, remove all the gasket material from the cylinder block surface.
(c) Using compressed air, blow carbon and oil from the bolt holes.
CAUTION:
Protect your eyes when using high −compressed air.
2. CLEAN CYLINDER HEAD
(a) Using a gasket scraper, remove all the gasket material from the cylinder block contact surface.
NOTICE:
Be careful not to scratch the cylinder block contact sur-
face.
(b) Using a wire brush, remove all the carbon from the com- bustion chambers.
NOTICE:
Be careful not to scratch the cylinder block contact sur-
face.
(c) Using a valve guide bushing brush and solvent, clean all the guide bushings.
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