Engine oil TOYOTA LAND CRUISER 1996 J80 Repair Manual

Z00054
44.5°
EM0181
Margin Thickness
EM−42
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ENGINE MECHANICAL CYLINDER HEAD
1996 LAND CRUISER (RM451U)
5. INSPECT VALVE STEMS AND GUIDE BUSHINGS
(a) Using a cali per gauge, measure the inside diameter of the
guide bushing.
Bushing inside diameter:
7.010 − 7.030 mm (0.2760 − 0.2768 in.)
(b) Using a micrometer, measure the diameter of the valve stem.
Valve stem diameter:
Intake6.970 − 6.985 mm (0.2744 − 0.2750 in.)
Exhaust6.965 − 6.980 mm (0.2742 − 0.2748 in.)
(c) Subtract the valve stem diameter measurement from the
guide bushing inside diameter measurement.
Standard oil clearance:
Intake0.025 − 0.060 mm (0.0010 − 0.0024 in.)
Exhaust0.030 − 0.065 mm (0.0012 − 0.0026 in.)
Maximum oil clearance:
Intake0.08 mm (0.0031 in.)
Exhaust0.10 mm (0.0039 in.)
If the clearance is greater than maximum, replace the valve and
guide bushing (See page EM−49).
6. INSPECT AND GRIND VALVES
(a) Grind the valve enough to remove pits and carbon.
(b) Check that the valve is ground to the correct valve face angle.
Valve face angle: 44.5°
(c) Check the valve head margin thickness. Margin thickness:
Standard1.2 mm (0.047 in.)
Minimum1.0 mm (0.039 in.)
If the margin thickness is less than minimum, replace the valve.
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EM0281
P03976
P03977
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ENGINE MECHANICAL CYLINDER HEAD
EM−45
1996 LAND CRUISER (RM451U)
(c) Using a spring tester, measure the tension of the valve
spring at the specified installed length.
Installed tension:
214 − 238 N (21.8 − 24.2 kgf, 48.1 − 53.4 lbf)
at 36.5 mm (1.437 in.)
If the installed tension is not as specified, replace the valve
spring.
9. INSPECT CAMSHAFTS
(a) Inspect for runout. (1) Place the camshaft 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 cam-
shaft.
(b) Inspect the cam lobes. Using a micrometer, measure the cam lobe height.
Standard cam lobe height:
50.61 − 50.71 mm (1.9925 − 1.9965 in.)
Minimum cam lobe height: 50.51 mm (1.9886 in.)
If the cam lobe height is less than minimum, replace the cam-
shaft.
(c) Inspect the journals. Using a micrometer, measure the journal diameter.
Journal diameter:
26.959 − 26.975 mm (1.0614 − 1.0620 in.)
If the journal diameter is not as specified, check the oil clear-
ance.
(d) Inspect the camshaft bearings. Check that bearings for flaking and scoring.
If the bearings are damaged, replace the bearing caps and cyl-
inder head as a set.
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EM3322
EM−46
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ENGINE MECHANICAL CYLINDER HEAD
1996 LAND CRUISER (RM451U)
(e) Inspect the gear spring
Using vernier calipers, measure the free distance be-
tween the spring ends.
Free distance: 18.2 − 18.8 mm (0.717 − 0.740 in.)
If the free distance is not as specified, replace the gear spring.
(f) Inspect the journal oil clearance. (1) Clean the bearing caps and camshaft journals.
(2) Place the camshafts on the cylinder head.
(3) Lay a strip of Plastigage across each of the cam-
shaft journals.
(4) Install the bearing caps (See page EM−54).
NOTICE:
Do not turn the camshaft. (5) Remove the bearing caps.
(6) Measure the Plastigage at its widest point.
Standard oil clearance:
0.025 − 0.062 mm (0.0010 − 0.0024 in.)
Maximum oil clearance: 0.10 mm (0.0039 in.)
If the oil clearance is greater than maximum, replace the cam-
shaft. If necessary, replace the bearing caps and cylinder head
as a set. (7) Completely remove the Plastigage.
(g) Inspect the thrust clearance. (1) Install the camshaft (See page EM−54 ).
(2) Using a dial indicator, measure the thrust clearance
while moving the camshaft back and forth.
Standard thrust clearance:
0.030 − 0.080 mm (0.0012 − 0.0031 in.)
Maximum thrust clearance: 0.10 mm (0.0039 in.)
If the thrust clearance is greater than maximum, replace the
camshaft. If necessary, replace the bearing caps and cylinder
head as a set.
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EM2196
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ENGINE MECHANICAL CYLINDER HEAD
EM−47
1996 LAND CRUISER (RM451U)
(h) Inspect the gear backlash.
(1) Install the camshafts without installing the exhaustcam sub−gear (See page EM−54).
(2) Using a dial indicator, measure the backlash.
Standard backlash:
0.020 − 0.200 mm (0.0008 − 0.0079 in.)
Maximum backlash: 0.30 mm (0.0188 in.)
If the backlash is greater than maximum, replace the cam-
shafts.
10. INSPECT VALVE LIFTER OIL CLEARANCE
(a) Using a caliper gauge, measure the lifter bore diameter of the cylinder head.
Lifter bore diameter:
34.000 − 34.021 mm (1.3386 − 1.3394 in.)
(b) Using a micrometer, measure the lifter diameter. Lifter diameter:
33.966 − 33.976 mm (1.3372 − 1.3376 in.)
(c) Subtract the lifter diameter measurement from the lifter bore diameter measurement.
Standard oil clearance:
0.024 − 0.055 mm (0.0009 − 0.0022 in.)
Maximum oil clearance: 0.07 mm (0.0028 in.)
If the oil clearance is greater than maximum, replace the lifter.
If necessary, replace the cylinder head.
11. INSPECT AIR INTAKE CHAMBER
Using a precision straight edge and thickness gauge, measure
the surface contacting the intake manifold for warpage. Maximum warpage: 0.30 mm (0.0118 in.)
If warpage is greater than maximum, replace the air intake
chamber.
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EM1E6−01
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ENGINE MECHANICAL CYLINDER HEAD
EM−51
1996 LAND CRUISER (RM451U)
REASSEMBLY
HINT:
Thoroughly clean all parts to be assembled.
Before installing the parts, apply new engine oil to all slid-
ing and rotating surfaces.
Replace all gaskets and oil seals with new ones.
1. INSTALL SPARK PLUG TUBES
HINT:
When using a new cylinder head, spark plug tubes must be
installed.
(a) Mark the standard position away from the edge, onto the spark plug tube.
Standard protrusion: 45.5 mm (1.791 in.)
(b) Apply adhesive to the spark plug tube hole of the cylinder
head.
Sealant:
Part No. 08833−00070, Adhesive 1324, THREE BOND
1324 or equivalent
(c) Using a press, press in a new spark plug tube until there is 45.5 mm (1.791 in.) protruding from the camshaft bear-
ing cap installation surface of the cylinder head.
NOTICE:
Avoid pressing a new spark plug tube in too far by measur-
ing the amount of protrusion while pressing.
2. INSTALL TVV
(a) Apply adhesive to 2 or 3 threads of the TVV. Adhesive:
Part No.08833 −00080, THREE BOND 1344, LOCTITE
242 or equivalent
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EM−52
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ENGINE MECHANICAL CYLINDER HEAD
1996 LAND CRUISER (RM451U)
(b) Install the TVV.
3. INSTALL ECT SENDER GAUGE
4. INSTALL ECT CUT SWITCH
5. INSTALL ECT SENSOR
6. INSTALL VALVES
(a) Using SST, push in a new oil seal.
SST 09236−00101 (09236 −15010)
HINT:
Different oil seals are used for the intake and exhaust.
(b) Install the valve (1), spring seat (2), valve spring (3) and spring retainer (4).
(c) Using SST, compress the valve spring and place the 2 keepers around the valve stem.
SST 09202−70020 (09202 −00010)
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EM1E7−01
EM−54
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ENGINE MECHANICAL CYLINDER HEAD
1996 LAND CRUISER (RM451U)
INSTALLATION
1. INSTALL CYLINDER HEAD AND INTAKE MANIFOLD ASSEMBLY
(a) Place the cylinder head on the cylinder head. (1) Apply seal packing to the 2 locations as shown.
Seal packing: Part No. 08826−00080 or equivalent
NOTICE:
Do not apply too much seal packing
(2) Place a new cylinder head gasket in position on the
cylinder block.
NOTICE:
Be careful of the installation direction. (3) Place the cylinder head in position on the cylinderhead gasket.
(b) Install the cylinder head bolts.
HINT:
The cylinder head bolts are tightened in 3 progressive
steps (steps (b), (d) and (e)).
If any cylinder head bolt is broken or deformed, replace
it.
(1) Apply a light coat of engine oil on the threads and under the heads of the cylinder head bolts.
(2) Install and uniformly tighten the 14 cylinder head
bolts and plate washers in several passes, in the se-
quence shown.
Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)
If any of the cylinder head bolts does not meet the torque speci-
fication, replace the cylinder head bolt.
(3) Mark the front of the cylinder head bolt head withpaint.
(4) Retighten the cylinder head bolts by 90 ° in the nu-
merical order shown.
(5) Retighten the cylinder head bolts by an additional 90°.
(6) Check that the painted mark is now facing rearward.
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P22567A16077
2 Dot Marks
EM−56
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ENGINE MECHANICAL CYLINDER HEAD
1996 LAND CRUISER (RM451U)
(a) Install the intake camshaft.
(1) Apply engine oil to the thrust portion of the intakecamshaft.
(2) Lightly place the intake camshaft on top of the cylin-
der head as shown in the illustration so that the No.
1 and No. 4 cylinder cam lobes face downward.
(3) Lightly push the camshaft towards the front without
applying excessive force.
(4) Place the No. 2 and No. 5 bearing caps in their prop-
er location.
(5) Temporarily tighten these bearing cap bolts uni- formly and alternately in several passes until the
bearing caps are snug with the cylinder head.
(6) Place the No. 3, No. 4, No. 6 and No. 7 bearing caps
in their proper location.
(7) Temporarily tighten these bearing cap bolts, alter- nately tightening the left and right bolts uniformly.
(8) Place the No. 1 bearing cap in its proper location. When doing this, check that there is no gap be-
tween the cylinder head and the contact surface of
bearing cap.
(9) Temporarily tighten the bearing cap bolts, alternate-
ly tightening the left and right bolts uniformly.
(10) Uniformly tighten the 14 bearing cap bolts in several
passes.
Torque: 16 N·m (160 kgf·cm, 12 ft·lbf)
(b) Install the exhaust camshaft. (1) Set the timing mark (2 dot marks) of the camshaftdrive gear at approx. 35 ° angle by turning the hexa-
gon wrench head portion of the intake camshaft
with a wrench.
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ENGINE MECHANICAL CYLINDER HEAD
EM−57
1996 LAND CRUISER (RM451U)
(2) Apply engine oil to thrust portion of the exhaust
camshaft.
(3) Engage the exhaust camshaft gear to the intake
camshaft gear by matching the timing marks (two
dot marks) on each gear.
(4) Roll down the exhaust camshaft onto the bearing journals while engaging gears with each other.
(5) Lightly push the intake camshaft towards the front without applying excessive force.
(6) Install the No. 4 and No. 6 bearing caps in their proper location.
(7) Temporarily tighten the bearing cap bolts uniformly and alternately in several passes until the bearing
caps are snug with the cylinder head.
(8) Place the No. 2, No. 3, No. 5 and No. 7 bearing caps
in their proper location.
(9) Temporarily tighten these bearing cap bolts, alter- nately tightening the left and right bolts uniformly.
(10) Place the No. 1 bearing cap in its proper location. When doing this, check that there is no gap be-
tween the cylinder head and the contact surface of
bearing cap.
(11) Temporarily tighten the bearing cap bolts, alternate-
ly tightening the left and right bolts uniformly.
(12) Uniformly tighten the 14 bearing cap bolts in several
passes.
Torque: 16 N·m (160 kgf·cm, 12 ft·lbf)
(13) Bring the service bolt installed in the driven sub −
gear upward by turning the hexagon wrench head
portion of the camshaft with a wrench.
(14) Remove the service bolt.
(15) Check that the intake and exhaust camshafts turn smoothly.
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EM−62
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ENGINE MECHANICAL CYLINDER HEAD
1996 LAND CRUISER (RM451U)
(h) Connect the engine wire to the intake manifold and cylin-
der block with the 2 bolts.
(i) Connect the PNP switch connector.
(j) Connect the 2 heated oxygen sensor connectors.
(k) Connect the connectors.
(1) Connect the Knock sensor connector.
(2) Connect the oil level sensor connector.
(3) Connect the 2 connectors to tthe ransmission.
(4) Connect the starter connector.
(l) Connect the engine wire to the cylinder block with the bolt.
(m) Connect the connectors.
(1) Connect the ECT sender gauge connector.
(2) Connect the ECT cut switch connector.
(3) Connect the ECT sensor connector.
(4) Connect the knock sensor connector.
(5) Connect the crankshaft position sensor connector.
19. CONNECT FUEL INLET HOSE
Connect the fuel inlet hose to the fuel filter with 2 new gaskets
and the union bolt. Torque: 29 N·m (300 kgf·cm, 22 ft·lbf)
20. INSTALL INTAKE MANIFOLD STAY
Install the intake manifold stay with the 2 bolts. Torque: 36 N·m (360 kgf·cm, 26 ft·lbf)
21. INSTALL OIL DIPSTICKS AND GUIDES FOR ENGINE AND TRANSMISSION
(a) Install a new O−ring to the dipstick guide.
(b) Apply a light coat of engine oil on the O −ring.
(c) Push in the dipstick guide into the guide hole of the oil pan.
(d) Install the dipstick guide with the 2 bolts. Torque: 20 N·m (200 kgf·cm, 14 ft·lbf)
22. INSTALL THROTTLE BODY (See page SF−48)
23. INSTALL GENERATOR AND DRIVE BELTS (See page CH−19 )
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