TOYOTA LAND CRUISER 1998 Factory Repair Manual

A05095
1
2
4
8
6
3
5
97
10
A05093
A05097
Plastigage
A05095
EM-92
- ENGINE MECHANICALCYLINDER BLOCK
1665 Author
: Date
:
2004 LAND CRUISER (RM1071U)
23. REMOVE MAIN BEARING CAPS AND CHECK OIL
CLEARANCE
(a) Evenly loosen and remove the 10 main bearing cap bolts
a little at time for several times, in the sequence shown.
(b) Using 2 screwdrivers, pry out the main bearing cap, and
remove the 5 main bearing caps, the 5 lower bearings and
the 2 lower thrust washers (No.3 main bearing cap only).
NOTICE:
Be careful not to damage the cylinder block.
HINT:

Keep the lower bearing and the main bearing cap togeth-
er.

Arrange the main bearing caps and lower thrust washers
in correct order.
(c) Lift out the crankshaft.
HINT:
Keep the upper bearings and the upper thrust washers together
with the cylinder block.
(d) Clean each main journal and bearing.
(e) Check each main journal and bearing for pitting and
scratches.
If the journal or bearing is damaged, replace the bearings. If
necessary, replace the crankshaft.
(f) Place the crankshaft on the cylinder block.
(g) Lay a strip of plastigage across each journal.
(h) Install the main bearing caps.
(See page EM-107)
NOTICE:
Do not turn the crankshaft.
(i) Remove the main bearing caps.
(See procedure (a) and (b) above)

A05098
A05089A05088A05090A05176
Number Mark
Number
Mark
Number
Mark No.1No.2 No.3No.4 No.5
No.1No.2
No.3
No.4No.5
Cylinder block (A)
Crankshaft (B)Use bearing
+
24 - 28 18 - 23 12 - 176 - 11 0 - 5 No.1, No.5:
EXAMPLE:
Cylinder block º08º + Crankshaft º06º
= Total number 14 (Use bearing º5º)3
4
5
6
7
Cylinder block (A)
Crankshaft (B)Use bearing
+
24 - 28 18 - 23 12 - 176 - 11 0 - 5
EXAMPLE:
Cylinder block º08º + Crankshaft º06º
= Total number 14 (Use bearing º3º)3
4
5 1
2 Others:
- ENGINE MECHANICALCYLINDER BLOCK
EM-93
1666 Author
: Date
:
2004 LAND CRUISER (RM1071U)
(j) Measure the plastigage at its widest point.
Standard clearance:
0.040 - 0.058 mm (0.0016 - 0.0023 in.)
Maximum clearance: 0.070 mm (0.0028 in.)
If the oil clearance is greater than the maximum, replace the
bearings. If necessary, replace the crankshaft.
HINT:
If using a standard bearing, replace it with the one having the
same number. If the number of the bearing cannot be deter-
mined, sum up the numbers imprinted on the cylinder block and
the crankshaft, then refer to the table below for the appropriate
bearing number. There are 5 sizes of the standard bearings. For
No.1 and No.5 position bearings, use bearings marked º3º, º4º,
º5º, º6º and º7º. For others position bearings, use bearings
marked º1º, º2º, º3º, º4º and º5º.
Reference
Cylinder block main journal bore diameter (A):
Mark º00º72.000 mm (2.8346 in.)
Mark º01º72.001 mm (2.8347 in.)
Mark º02º72.002 mm (2.8347 in.)
Mark º03º72.003 mm (2.8348 in.)
Mark º04º72.004 mm (2.8348 in.)
Mark º05º72.005 mm (2.8348 in.)
Mark º06º72.006 mm (2.8349 in.)
Mark º07º72.007 mm (2.8349 in.)

EM-94
- ENGINE MECHANICALCYLINDER BLOCK
1667 Author
: Date
:
2004 LAND CRUISER (RM1071U)Mark º08º
72.008 mm (2.8350 in.)
Mark º09º72.009 mm (2.8350 in.)
Mark º10º72.010 mm (2.8350 in.)
Mark º11º72.011 mm (2.8351 in.)
Mark º12º72.012 mm (2.8351 in.)
Mark º13º72.013 mm (2.8352 in.)
Mark º14º72.014 mm (2.8352 in.)
Mark º15º72.015 mm (2.8352 in.)
Mark º16º72.016 mm (2.8353 in.)
Crankshaft main journal diameter (B):
Mark º00º67.000 mm (2.6378 in.)
Mark º01º66.999 mm (2.6378 in.)
Mark º02º66.998 mm (2.6377 in.)
Mark º03º66.997 mm (2.6377 in.)
Mark º04º66.996 mm (2.6376 in.)
Mark º05º66.995 mm (2.6376 in.)
Mark º06º66.994 mm (2.6376 in.)
Mark º07º66.993 mm (2.6375 in.)
Mark º08º66.992 mm (2.6375 in.)
Mark º09º66.991 mm (2.6374 in.)
Mark º10º66.990 mm (2.6374 in.)
Mark º11º66.989 mm (2.6374 in.)
Mark º12º66.988 mm (2.6373 in.)
Standard bearing center wall thickness:
No.1 and No.5
Mark º3º2.481 - 2.484 mm (0.0977 - 0.0978 in.)
Mark º4º2.484 - 2.487 mm (0.0978 - 0.0979 in.)
Mark º5º2.487 - 2.490 mm (0.0979 - 0.0980 in.)
Mark º6º2.490 - 2.493 mm (0.0980 - 0.0981 in.)
Mark º7º2.493 - 2.496 mm (0.0981 - 0.0983 in.)
Others:
Mark º1º2.481 - 2.484 mm (0.0977 - 0.0978 in.)
Mark º2º2.484 - 2.487 mm (0.0978 - 0.0979 in.)
Mark º3º2.487 - 2.490 mm (0.0979 - 0.0980 in.)
Mark º4º2.490 - 2.493 mm (0.0980 - 0.0981 in.)
Mark º5º2.493 - 2.496 mm (0.0981 - 0.0983 in.)
(k) Completely remove the plastigage.

A04862
A04873
A04860
A04887
- ENGINE MECHANICALCYLINDER BLOCK
EM-95
1668 Author
: Date
:
2004 LAND CRUISER (RM1071U)
24. REMOVE CRANKSHAFT
(a) Lift up the crankshaft.
(b) Remove the 5 upper main bearings and the 2 upper thrust
washers from the cylinder block.
HINT:
Arrange the main bearing caps, bearings and thrust washers in
correct order for installation.
25. 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.
26. REMOVE PISTON RINGS
(a) Using a piston ring expander, remove the 2 compression
rings.
(b) Remove the 2 side rails and the oil ring by hand.
HINT:
Arrange the piston rings in correct order for installation.
27. DISCONNECT CONNECTING ROD FROM PISTON
(a) Using a small screwdriver, pry out the 2 snap rings.
(b) Gradually heat the piston to approx. 60°C (140°F).

A04888
EM-96
- ENGINE MECHANICALCYLINDER BLOCK
1669 Author
: Date
:
2004 LAND CRUISER (RM1071U)
(c) Using a plastic-faced hammer and a brass bar, lightly tap
out the piston pin and the pin and remove the connecting
rod.
HINT:

The piston and the pin are the set.

Arrange the pistons, the pins, the rings, the connecting
rods and the bearings in correct order for installation.

EM0EB-13
A04849
A04850A04210A04212A05178
Cylinder Block Side
Main Bearing Cap Side
A04853
- ENGINE MECHANICALCYLINDER BLOCK
EM-97
1670 Author
: Date
:
2004 LAND CRUISER (RM1071U)
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 a feeler gauge, mea-
sure the surfaces contacting the cylinder head and main
bearing cap for a warp.
Maximum warpage: 0.07 mm (0.0028 in.)
If the warp is greater than the maximum, replace the cylinder
block.
(b) Visually check the cylinder for vertical scratches.
If deep scratches are found, rebore all the 8 cylinders and re-
place all the 8 pistons (See page EM-104). If necessary, re-
place the cylinder block.

A04211Mark 1, 2 or 3 Front
No.2 No.4 No.6 No.8
No.1 No.3 No.4 No.5
:
A04262A04851A05181
1
2
B
C
AThrust
Direction
Axial
Direction
10 mm
(0.39 in.)
10 mm
(0.39 in.) Front
1
2
1
A04852
Ridge
Reamer
A0513850 - 64 mm (1.97 - 2.52 in.) EM-98
- ENGINE MECHANICALCYLINDER BLOCK
1671 Author
: Date
:
2004 LAND CRUISER (RM1071U)
(c) Inspect the cylinder bore diameter.
HINT:
There are 3 sizes of the standard cylinder bore diameter,
marked º1º, º2º and º3º accordingly. The mark is stamped on the
top of the cylinder block.
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 º1º94.002 - 94.010 mm (3.7009 - 3.7012 in.)STD Mark 1
Mark º2º
94.002 - 94.010 mm (3.7009 - 3.7012 in.)
94.010 - 94.023 mm (3.7012 - 3.7017 in.)Mark 2
Mark º3º
94.010 94.023 mm (3.7012 3.7017 in.)
94.023 - 94.031 mm (3.7017 - 3.7020 in.)
Maximum diameter: 94.23 mm (3.7098 in.)
STD94.231 mm (3.7099 in.)
O/S 0.5094.731 mm (3.7296 in.)
If the diameter is greater than the maximum, rebore all the 8 cyl-
inders and replace all the 8 pistons (See page EM-104). If nec-
essary, 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) Using vernier calipers, measure the thread outside diam-
eter of the main bearing cap bolt.
Standard diameter:
10.760 - 10.970 mm (0.4236 - 0.4319 in.)
Minimum diameter: 10.40 mm (0.4094 in.)
If the diameter is less than the minimum, replace the cap bolt.

A04877
A04878
A04879
A04874
A04885A05180
Mark 1, 2 or 3Mark 1, 2 or 3
LH
Piston
RH
Piston
30.75 mm
- ENGINE MECHANICALCYLINDER BLOCK
EM-99
1672 Author
: Date
:
2004 LAND CRUISER (RM1071U)
3. 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.
4. INSPECT PISTON AND CONNECTING ROD
(a) Inspect the piston oil clearance.
HINT:
There are 3 sizes of the standard piston diameter, marked º1º,
º2º and º3º accordingly. The mark is stamped on the piston top.
(1) Using a micrometer, measure the piston diameter at
right angles to the piston pin center line, 30.75 mm
(1.2106 in.) from the piston head.
Piston diameter:
STD Mark º1º93.902 - 93.912 mm (3.6969 - 3.6973 in.)STD Mark 1
Mark º2º
93.902 - 93.912 mm (3.6969 - 3.6973 in.)
93.912 - 93.920 mm (3.6973 - 3.6976 in.)Mark 2
Mark º3º
93.912 93.920 mm (3.6973 3.6976 in.)
93.920 - 93.930 mm (3.6976 - 3.6980 in.)
O/S 0.5094.402 - 94.430 mm (3.7166 - 3.7177 in.)
(2) Measure the cylinder bore diameter in the thrust
directions. (See step 2 above)
(3) Subtract the piston diameter from the cylinder bore
diameter.

A04211A04875A04885A05179
Cylinder Block
Front
No.2 No.4 No.6
No.8
No.1
No.5 No.7
RH Piston
No.3
:
LH PistonMark 1, 2 or 3
Mark 1, 2 or 3Mark 1, 2 or 3
A04880
EM-100
- ENGINE MECHANICALCYLINDER BLOCK
1673 Author
: Date
:
2004 LAND CRUISER (RM1071U)
Standard oil clearance:
0.090 - 0.111 mm (0.0035 - 0.0044 in.)
Maximum oil clearance: 0.13 mm (0.0051 in.)
If the oil clearance is greater than the maximum, replace all the
8 pistons and rebore all the 8 cylinders. (See page EM-104) If
necessary, replace the cylinder block.
HINT
Use new cylinder block:

Use a piston with the same number mark as the cylinder
diameter marked on the cylinder block.

The shape of the piston varies for the LH and the RH
banks. The LH piston is marked as ºLHº and º2Lº, and the
RH piston as ºRHº and º2Rº.
(b) Inspect the piston ring groove clearance.
Using a feeler gauge, measure the clearance between
new piston ring and the wall of the ring groove.
Ring groove clearance:
No.10.030 - 0.080 mm (0.0012 - 0.0031 in.)
No.20.030 - 0.070 mm (0.0012 - 0.0028 in.)
If the clearance is not as specified, replace the piston.

A04872
105 mm
EM7639
A04048
60°C
Z14454
- ENGINE MECHANICALCYLINDER BLOCK
EM-101
1674 Author
: Date
:
2004 LAND CRUISER (RM1071U)
(c) Inspect the piston ring end gap.
(1) Insert the piston ring into the cylinder bore.
(2) Using a piston, push the piston ring to a little beyond
the bottom of the ring travel, 105 mm (4.13 in.) from
the top of the cylinder block.
(3) Using a feeler gauge, measure the end gap.
Standard end gap:
No.10.300 - 0.500 mm (0.0118 - 0.0197 in.)
No.20.400 - 0.650 mm (0.0157 - 0.0256 in.)
Oil (Side rail)0.130 - 0.480 mm (0.0051 - 0.0189 in.)
Maximum end gap:
No.11.10 mm (0.0433 in.)
No.21.20 mm (0.0472 in.)
Oil (Side rail)1.15 mm (0.0453 in.)
If the end gap is greater than the maximum, replace the piston
ring. If the end gap is greater than the maximum, even with a
new piston ring, rebore all the 8 cylinders (See page EM-104)
or replace the cylinder block.
(d) Inspect the piston pin fit.
At 60°C (140°F), you should be able to push the piston
pin into the piston pin hole with your thumb.
(e) Using a rod aligner and the feeler gauge, check the con-
necting rod alignment.
(1) Check for bend.
Maximum bend:
0.05 mm (0.0020 in.) per 100 mm (3.94 in.)
If bend is greater than maximum, replace the connecting rod as-
sembly.