TOYOTA LAND CRUISER 1998 Factory Repair Manual
Manufacturer: TOYOTA, Model Year: 1998, Model line: LAND CRUISER, Model: TOYOTA LAND CRUISER 1998Pages: 3115, PDF Size: 54.88 MB
Page 1841 of 3115
A05500
Upper Intake Manifold Side
Cylinder Head Side
A05501
A02827
Measuring Point
75 - 85 mm
(2.95 - 3.35 in.)
EM-54
- ENGINE MECHANICALCYLINDER HEAD
1627 Author: Date:
2004 LAND CRUISER (RM1071U)
(b) Lower intake manifold:
Using a precision straight edge and a feeler gauge, mea-
sure the surface contacting of the cylinder head and the
upper intake manifold for a warpage.
Maximum warpage:
0.15 mm (0.0059 in.)
If the warp is greater than the maximum, replace the lower in-
take manifold.
23. INSPECT EXHAUST MANIFOLD
Using a precision straight edge and a feeler gauge, measure
the surface contacting of the cylinder head for a warp.
Maximum warpage:
0.50 mm (0.0197 in.)
If the warp is greater than the maximum, replace the manifold.
24. INSPECT CYLINDER HEAD BOLTS
Using vernier calipers, measure the thread outside diameter of
the bolt.
Standard outside diameter:
9.810 - 9.960 mm (0.3862 - 0.3921 in.)
Minimum outside diameter:
9.700 mm (0.3819 in.)
If the diameter is less than the minimum, replace the bolt.
Page 1842 of 3115
A05594
White Painted
Mark
EM1V9-01
A05498
A05595
White Painted Mark
A05518
- ENGINE MECHANICALCYLINDER HEAD
EM-59
1632 Author: Date:
2004 LAND CRUISER (RM1071U)
INSTALLATION
1. INSTALL RH EXHAUST MANIFOLD TO CYLINDER
HEAD
(a) Place a new gasket on the cylinder head with the white
painted marks facing the manifold side.
NOTICE:
Be careful of the installation direction.
(b) Install the exhaust manifold with 8 new nuts. Evenly tight-
en the nuts a little at a time for several times.
Torque: 44 N´m (450 kgf´cm, 32 ft´lbf)
(c) Install the heat insulator with the 4 bolts.
Torque: 7.5 N´m (77 kgf´cm, 66 in.´lbf)
2. INSTALL LH EXHAUST MANIFOLD TO CYLINDER
HEAD
(a) Place a new gasket on the cylinder head with the white
painted marks facing the manifold side.
NOTICE:
Be careful of the installation direction.
(b) Install the exhaust manifold with 8 new nuts. Evenly tight-
en the nuts a little at a time for several times.
Torque: 44 N´m (450 kgf´cm, 32 ft´lbf)
(c) Install the heat insulator with the 4 bolts.
Torque: 7.5 N´m (77 kgf´cm, 66 in.´lbf)
Page 1843 of 3115
A05563
RH Cylinder Head
LH Cylinder Head 2UR
2UL
A05714
RH Cylinder Head
LH Cylinder Head
179
4
6
5
3
10
8
217
96
5
3
10
8
2
1
4
Front EM-60
- ENGINE MECHANICALCYLINDER HEAD
1633 Author: Date:
2004 LAND CRUISER (RM1071U)
3. PLACE CYLINDER HEAD ON CYLINDER BLOCK
(a) Place 2 new cylinder head gaskets in position on the cylin-
der block.
HINT:
On the rear side of the cylinder head gasket, there is a mark to
distinguish the LH and RH banks, a º2URº for the RH bank and
a º2ULº for the LH bank.
NOTICE:
Be careful of the installation direction.
(b) Place the 2 cylinder heads in position on the cylinder head
gaskets.
4. INSTALL CYLINDER HEAD BOLTS
HINT:
The cylinder head bolts are tightened in 2 progressive
steps (steps (c) and (e)).
If any cylinder head bolt is broken or deformed, replace
it.
(a) Apply a light coat of engine oil on the threads and under
the heads of the cylinder head bolts.
(b) Install the plate washer to the cylinder head bolt.
(c) Install and evenly tighten the 10 cylinder head bolts on
one side of the cylinder head a little at a time for several
times as in the order shown, then do the other side as
shown.
Torque: 32 N´m (325 kgf´cm, 24 ft´lbf)
If any one of the cylinder head bolts does not meet the torque
specification, replace the cylinder head bolt.
Page 1844 of 3115
A04473
RH Cylinder Head
LH Cylinder HeadA
A
A11159
Painted Mark90°
180°
A02888
A02861
- ENGINE MECHANICALCYLINDER HEAD
EM-61
1634 Author: Date:
2004 LAND CRUISER (RM1071U)
NOTICE:
Do not drop the plate washer of the cylinder head bolt into
A area in the illustration. It will fall down to the oil pan
through the cylinder head and the cylinder block.
(d) Mark the front of the cylinder head bolt head with paint.
(e) Retighten the cylinder head bolts by 90° only for the first
time.
(f) Then retighten them by 90° further for the second time.
(g) Check that the painted mark is now at a 180° angle to the
front.
5. INSTALL SPARK PLUGS
6. ASSEMBLE EXHAUST CAMSHAFT
(a) Install the camshaft gear spring, the camshaft sub-gear
and the wave washer.
HINT:
Attach the pins on the gears to the gear spring ends.
(b) Using snap ring pliers, install the snap ring.
Page 1845 of 3115
A02859
A02889
Service Bolt
SST
Sub Gear
Main Gear
Turn
A02890
Seal Packing
A05502
RH Cylinder Head
LH Cylinder HeadFront EM-62
- ENGINE MECHANICALCYLINDER HEAD
1635 Author: Date:
2004 LAND CRUISER (RM1071U)
(c) Mount the hexagon shaped part of the camshaft in a vise.
NOTICE:
Be careful not to damage the camshaft.
(d) Using SST, align the holes of the camshaft main gear and
sub-gear by turning camshaft sub-gear counterclock-
wise, and temporarily install a service bolt.
SST 09960-10010 (09962-01000, 09963-00500)
(e) Align the gear teeth of the main gear and sub-gear, and
tighten the service bolt.
7. INSTALL CAMSHAFT HOUSING PLUGS
(a) Remove any old packing (FIPG) material.
(b) Apply seal packing to the camshaft housing plug grooves.
Seal packing:
Part No. 08826-00080 or equivalent
(c) Install the 2 camshaft housing plugs to the cylinder heads.
Page 1846 of 3115
A04336
Timing
MarkNo. 2 Idler Pulley Bolt
Turn
A05525
Approx. 10°
A05503
Seal Packing
Groove Seal Width
1.5 mm
- ENGINE MECHANICALCYLINDER HEAD
EM-63
1636 Author: Date:
2004 LAND CRUISER (RM1071U)
8. INSTALL CAMSHAFTS
NOTICE:
Since the thrust clearance of the camshaft is small, the
camshaft must be kept level while it is being removed.
Otherwise, excessive pressure is put on the cylinder head
journal thrust, causing a burr on the journal and damage on
the camshaft. To avoid this, follow the steps below.
(a) Set the crankshaft pulley position.
Turn the crankshaft pulley clockwise or counterclockwise,
and put the timing mark of the crankshaft pulley in line with
the centers of the crankshaft pulley bolt and the idler
pulley bolt.
NOTICE:
Having the crankshaft pulley at the wrong angle can cause
the piston head and the valve head to come into contact
with each other when removing the camshaft, causing
damage on them. So always set the crankshaft pulley at the
correct angle.
(b) Install the RH camshafts.
(1) Apply MP grease to the thrust portion of the intake
and exhaust camshafts.
(2) Place the intake and exhaust camshafts.
(3) Set the timing mark (1 dot mark) of the camshaft
main gear at approx. 10° angle.
(4) Remove any old packing (FIPG) material from the
front bearing cap.
(5) Apply seal packing to the front bearing cap as
shown in the illustration.
Seal packing:
Part No. 08826-00080 or equivalent
Install a nozzle that is cut to a 1.5 mm (0.06
in.) opening.
Parts must be assembled within 5 minutes
the seal packing application. Otherwise the
material must be removed and the packing
have to be reapplied.
Immediately remove nozzle from the tube
and reinstall cap.
NOTICE:
Do not apply seal packing to the front bearing cap grooves.
Page 1847 of 3115
A05504Front
A05505
Push
A04469
A
B
C
C
E
E
D
D
E
E
A04469
10
1
256789
1112 13
141516
1718
19
2022
3
4
21
EM-64
- ENGINE MECHANICALCYLINDER HEAD
1637 Author: Date:
2004 LAND CRUISER (RM1071U)
(6) Install the front bearing cap.
HINT:
Installing the front bearing cap will determine the thrust portion
of the camshaft.
(7) Install the other bearing cap in the sequence shown
with the arrow mark facing forward.
HINT:
Align the arrow marks at the front and rear of the cylinder head
with the mark on the bearing cap.
(8) Push in the camshaft oil seal.
(9) Apply a light coat of engine oil on the threads and
under the heads (D and E) of the bearing cap bolts.
HINT:
Do not apply engine oil under the heads of the bearing cap bolt
(A), (B) and (C).
(10) Install the oil feed pipe and the 22 bearing cap bolts
as shown.
HINT:
Bolt length:
94 mm (3.70 in.) for A
72 mm (2.83 in.) for B
25 mm (0.98 in.) for C
52 mm (2.05 in.) for D
38 mm (1.50 in.) for E
(11) Evenly tighten the 22 bearing cap bolts a little at a
time for several times as in the sequence shown.
Torque:
Bolt C:
7.5 N´m (80 kgf´cm, 69 in.´lbf)
Others
16 N´m (160 kgf´cm, 12 ft´lbf)
Page 1848 of 3115
A04467
Service Bolt
A05768
A05526
Seal Packing
GrooveSeal Width
1.5 mm
A05506
Front
- ENGINE MECHANICALCYLINDER HEAD
EM-65
1638 Author: Date:
2004 LAND CRUISER (RM1071U)
(12) Move a service bolt of the sub-gear upward by turn-
ing the hexagon shaped port of the exhaust cam-
shaft with a wrench.
(13) Remove the service bolt.
(c) Install the LH camshafts.
(1) Apply MP grease to the thrust portion of the intake
and exhaust camshafts.
(2) Place the intake and exhaust camshafts.
(3) Engage the intake to the exhaust gear by putting
the timing marks (2 dot marks) on each gear.
(4) Remove any old packing (FIPG) material.
(5) Apply seal packing to the front bearing cap.
Seal packing:
Part No. 08826-00080 or equivalent
Install a nozzle that is cut to a 1.5 mm (0.06
in.) opening.
Parts must be assembled within 5 minutes
the seal packing application. Otherwise the
material must be removed and the packing
have to be reapplied.
Immediately remove nozzle from the tube
and reinstall cap.
NOTICE:
Do not apply seal packing to the front bearing cap grooves.
(6) Install the front bearing cap.
HINT:
Installing the front bearing cap will determine the thrust portion
of the camshaft.
(7) Install the other bearing cap in the sequence shown
with the arrow mark facing forward.
HINT:
Align the arrow marks at the front and rear of the cylinder head
with the mark on the bearing cap.
Page 1849 of 3115
A05507
Push
A04470
E D E
C
A
E D
E C B
A04470
10
1
2
56789
111213
141516
17 18
19
2022
3
4
21
A02856
Service
Bolt
EM-66
- ENGINE MECHANICALCYLINDER HEAD
1639 Author: Date:
2004 LAND CRUISER (RM1071U)
(8) Push in the camshaft oil seal.
(9) Apply a light coat of engine oil on the threads and
under the heads (D and E) of the bearing cap bolts.
HINT:
Do not apply engine oil under the heads of the bearing cap bolt
(A), (B) and (C).
(10) Install the oil feed pipe and the 22 bearing cap bolts
as shown.
HINT:
Bolt length:
94 mm (3.70 in.) for A
72 mm (2.83 in.) for B
25 mm (0.98 in.) for C
52 mm (2.05 in.) for D
38 mm (1.50 in.) for E
(11) Uniformly tighten the 22 bearing cap bolts in several
passes, in the sequence shown.
Torque:
Bolt C:
7.5 N´m (80 kgf´cm, 69 in.´lbf)
Others
16 N´m (160 kgf´cm, 12 ft´lbf)
(12) Move a service bolt of the sub-gear upward by turn-
ing the hexagon shaped port of the exhaust cam-
shaft with a wrench.
(13) Remove the service bolt.
9. CHECK AND ADJUST VALVE CLEARANCE (See page
EM-4)
Turn the camshaft and the position the cam lobe upward, and
check and adjust the valve clearance.
Page 1850 of 3115
EM7143
Seal Packing
A07250
RH Cylinder Head
LH Cylinder Head
A05509
RH Cylinder Head
LH Cylinder HeadApply Seal Packing
Apply Seal Packing
- ENGINE MECHANICALCYLINDER HEAD
EM-67
1640 Author: Date:
2004 LAND CRUISER (RM1071U)
10. INSTALL SEMI-CIRCULAR PLUGS
(a) Remove any old packing (FIPG) material.
(b) Apply seal packing to the semi-circular plug grooves.
Seal packing:
Part No. 08826-00080 or equivalent
(c) Install the 4 semi-circular plugs to the cylinder heads.
11. INSTALL CYLINDER HEAD COVER
(a) Remove any old packing (FIPG) material.
(b) Apply seal packing to the cylinder heads as shown in the
illustration.
Seal packing:
Part No. 08826-00080 or equivalent
(c) Install the gasket to the cylinder head cover.
(d) Install the seal washer to the bolt.
(e) Install the cylinder head cover with the 18 bolts. Evenly
tighten the bolts a little at a time for several times. Install
the 2 cylinder head covers.
Torque: 6.0 N´m (60 kgf´cm, 53 in.´lbf)
12. INSTALL ENGINE HANGERS
Torque: 37 N´m (380 kgf´cm, 27 ft´lbf)
13. INSTALL OIL DIPSTICK AND GUIDE FOR ENGINE