TOYOTA LAND CRUISER 1998 Factory Repair Manual

A05517
A05516
A08655
A03190
White Painted
Mark
A17671A19482
EM-68
- ENGINE MECHANICALCYLINDER HEAD
1641 Author
: Date
:
2004 LAND CRUISER (RM1071U)
14. INSTALL REAR WATER BYPASS JOINT
(a) Install 2 new gaskets to the cylinder head.
(b) Install the 4 nuts holding the water bypass joint to the cyl-
inder heads. Alternately tighten the nuts.
Torque: 18 N´m (185 kgf´cm, 13 ft´lbf)
15. INSTALL FRONT WATER BYPASS JOINT
Install 2 new gaskets and the water bypass joint with the 4 nuts.
Alternately tighten the nuts.
Torque: 18 N´m (185 kgf´cm, 13 ft´lbf)
16. INSTALL WATER INLET AND INLET HOUSING AS-
SEMBLY (See page CO-8)
17. ASSEMBLE UPPER AND LOWER INTAKE MAN-
IFOLDS
(a) Install the 2 delivery pipes and the 8 injectors (See page
SF-27).
(b) Install new 2 gaskets, the fuel pressure regulator and the
fuel pulsation damper.
(c) Install the fuel return hose to the lower intake manifold
with the 3 bolts.
(d) Connect the fuel return hose to the fuel pressure regula-
tor.
18. INSTALL INTAKE MANIFOLD ASSEMBLY
(a) Place 2 new gaskets on the cylinder heads with white
painted mark facing upward.
NOTICE:

Align the port holes of the gasket and cylinder head.

Be careful of the installation direction.
(b) Place the intake manifold assembly on the cylinder
heads.
(c) Install and uniformly tighten the 6 bolts and the 4 nuts in
several passes.
Torque: 18 N´m (185 kgf´cm, 13 ft´lbf)

A05514
A19472
A05562
B01208
A17668A19481
(p)
(o)
(n)
(m)(r)
(q)
- ENGINE MECHANICALCYLINDER HEAD
EM-69
1642 Author
: Date
:
2004 LAND CRUISER (RM1071U)
(d) Install the EVAP pipe to the intake manifold with the 2
bolts.
(e) Connect the wire protector to the intake manifold with the
2 bolts.
(f) Install the engine wire to the engine hanger.
(g) Install the engine wire to the LH No.1 timing belt rear
plate.
(h) Install the engine wire to the bracket.
(i) Connect the wire protector to the rear water bypass joint
and RH cylinder head with the 2 bolts.
(j) Install the 2 ground cables to the RH and LH cylinder
head.
(k) Install the guide for A/T bracket to the LH cylinder head.
(l) Connect the 2 wire clamps to the wire clamp bracket on
the RH delivery pipe.
(m) Connect the fuel pressure regulator vacuum hose to the
fuel pressure regulator pipe.
(n) Connect the PCV hose to the PCV valve on the LH cylin-
der head.
(o) Connect the EVAP hose (from charcoal canister) to the
VSV for EVAP.
(p) Connect the EVAP hose (from charcoal canister) to the
EVAP pipe on the intake manifold.
(q) Connect the EVAP hose (from intake air connector) to
EVAP pipe on the the intake manifold.

B15320B16469No. 1 Water Bypass Hose
EM-70
- ENGINE MECHANICALCYLINDER HEAD
1643 Author
: Date
:
2004 LAND CRUISER (RM1071U)
(r) Connect the PS air hose to intake manifold.
(s) Connect the No.1 water bypass hose (from water inlet
housing) to throttle body.
(t) Connect the throttle control connector.
(u) Connect the VSV connector for EVAP.
(v) Connect the 8 injector connectors.
(w) Connect the ECT sensor.
(x) Connect the water sender gauge.
(y) Connect the 8 ignition coil connectors.
(z) Connect the 2 oxygen sensor connectors.
19. CONNECT FUEL INLET HOSE (See page SF-24)
20. INSTALL TIMING BELT REAR PLATES
(a) Install the RH timing belt rear plates.
Install the No.1 timing belt rear plate to the cylinder head
with the 3 bolts and the stud bolt.
Torque: 7.5 N´m (80 kgf´cm, 66 in.´lbf)
(b) Install the LH timing belt rear plates.
(1) Connect the wire clamp to the No.1 timing belt rear
plate.
(2) Install the No.1 timing belt rear plate to the cylinder
head with the 3 bolts.
Torque: 7.5 N´m (80 kgf´cm, 66 in.´lbf)
21. INSTALL V-BANK COVER
Install the 3 V-bank covers.
Torque: 7.5 N´m (80 kgf´cm, 66 in.´lbf)
22. INSTALL IGNITION COILS (See page IG-6)
23. INSTALL OIL DIPSTICK AND GUIDE FOR A/T
24. INSTALL FRONT EXHAUST PIPE (See page EM-1 15)
25. INSTALL PS PUMP (See page EM-81)
26. INSTALL CAMSHAFT POSITION SENSOR (See page
IG-10)
27. INSTALL CAMSHAFT TIMING PULLEYS
(See page EM-22)
28. CONNECT TIMING BELT TO CAMSHAFT TIMING PUL-
LEYS (See page EM-22)
29. CHECK ENGINE OIL LEVEL

EM0L4-08
P08885
Adhesive
15 mm (0.59 in.)
A03212
Protrusion
A05710
SST
A05711
(1)(2)(3)(4)
- ENGINE MECHANICALCYLINDER HEAD
EM-57
1630 Author
: Date
:
2004 LAND CRUISER (RM1071U)
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, the spark plug tubes must be
installed.
(a) Apply adhesive to the end of the spark plug tube.
Adhesive:
Part No. 08833-00070, THREE BOND 1324
or equivalent
(b) Using a wooden block and hammer, tap in a new spark
tube until the protrusion from the camshaft bearing cap
installation surface of the cylinder head becomes 48.4 -
49.6 mm (1.906 - 1.953 in.).
NOTICE:
Avoid tapping a new spark plug tube in too far by measur-
ing the amount of the protrusion as tapping.
2. INSTALL VALVES
(a) Using SST, push in a new oil seal.
SST 09201-41020
(b) Install the valve (1), the spring seat (2), the valve spring
(3),and the spring retainer (4).

A05712
SST
A07306
EM-58
- ENGINE MECHANICALCYLINDER HEAD
1631 Author
: Date
:
2004 LAND CRUISER (RM1071U)
(c) Using SST, compress the valve spring and place the 2
keepers around the valve stem.
SST 09202-70020
(d) Using a plastic-faced hammer and the valve stem tip
taped up with vinyl tape, lightly tap the valve stem tip to
assure proper fit.
NOTICE:
Be careful not to damage the valve stem tip.
3. INSTALL SHIMS AND VALVE LIFTERS
(a) Install the shim and the valve lifter.
(b) Check that the valve lifter rotates smoothly by hand.

EM1V8-01
A02844
- ENGINE MECHANICALCYLINDER HEAD
EM-35
1608 Author
: Date
:
2004 LAND CRUISER (RM1071U)
REMOVAL
1. DRAIN ENGINE COOLANT
2. REMOVE V-BANK COVER
Remove the V-bank covers.
3. DISCONNECT TIMING BELT FROM CAMSHAFT TIM-
ING PULLEYS (See page EM-15)
4. REMOVE CAMSHAFT TIMING PULLEYS (See page
EM-15)
5. REMOVE CAMSHAFT POSITION SENSOR (See page
IG-9)
6. DISCONNECT PS PUMP FROM ENGINE
(See page EM-77)
7. REMOVE FRONT EXHAUST PIPE (See page EM-1 15)
8. REMOVE OIL DIPSTICK AND GUIDE FOR A/T
9. REMOVE IGNITION COILS (See page IG-6)
10. REMOVE TIMING BELT REAR PLATES
(1) Remove the 3 bolts, the stud bolt, and the RH No.1
timing belt rear plates.
(2) Disconnect the wire clamp from the LH timing belt
rear plate.
(3) Remove the 3 bolts, the stud bolt, the LH No.1 and
the timing belt rear plates.
NOTICE:

Be careful not to drop anything inside the timing belt
cover.

Do not allow the belt to contact correct with oil, water
or dust.
11. DISCONNECT FUEL INLET HOSE (See page SF-24)
12. REMOVE INTAKE MANIFOLD ASSEMBLY
(a) Disconnect the throttle control connector.
(b) Disconnect the VSV connector for EVAP.
(c) Disconnect the 8 injector connectors.
(d) Disconnect the ECT sensor connector.
(e) Disconnect the water sender gauge connector.
(f) Disconnect the 8 ignition coil connectors.
(g) Disconnect the 2 oxygen sensor connectors.

A17668A19481
(k)
(j)(i)
(n)(m)
(l)
B15320B16469No. 1 Water Bypass Hose
A17670
Wire Clamp
A08664
Wire Protector
Ground Cable
EM-36
- ENGINE MECHANICALCYLINDER HEAD
1609 Author
: Date
:
2004 LAND CRUISER (RM1071U)
(h) Disconnect the fuel pressure regulator vacuum hose from
the fuel pressure regulator pipe.
(i) Disconnect the PCV hose from the PCV valve on the LH
cylinder head.
(j) Disconnect the EVAP hose (from charcoal canister) from
VSV for EVAP.
(k) Disconnect the EVAP hose (from charcoal canister) from
the EVAP pipe on the intake manifold.
(l) Disconnect the EVAP hose (from intake air connector)
from the EVAP pipe on the intake manifold.
(m) Disconnect the PS air hose from the intake manifold.
(n) Disconnect the No.1 water bypass hose from the front wa-
ter by-pass joint.
(o) Disconnect the 2 wire clamps from the wire clamp bracket
on the RH delivery pipe.
(p) Remove the 2 bolts and disconnect the engine wire pro-
tector from the rear water bypass joint and the RH cylinder
head.
(q) Remove the guide for A/T bracket from the LH cylinder
head.
(r) Remove the 2 ground cables from the RH and LH cylinder
head.

A19472
A17671A19482
A17679
A09148
EVAP Pipe
A08655
- ENGINE MECHANICALCYLINDER HEAD
EM-37
1610 Author
: Date
:
2004 LAND CRUISER (RM1071U)
(s) Remove the 2 bolts and disconnect the engine wire pro-
tector from the intake manifold.
(t) Remove the engine wire from the engine hanger.
(u) Remove the engine wire from the wire bracket.
(v) Remove the RH rear and the LH front V-bank cover
brackets.
(w) Remove the 6 bolts, the 4 nuts, the intake manifold as-
sembly and the 2 gaskets.
13. DISASSEMBLE UPPER AND LOWER INTAKE MAN-
IFOLDS
(a) Remove the throttle body (See page SF-36).
(b) Remove the 13 bolts, the 3 nuts, the upper intake man-
ifold and the gasket.
(c) Disconnect the EVAP hose from the upper intake man-
ifold, and remove the accelerator cable clamp and VSV
for EVAP.
(d) Remove the bolt, the union, the 2 gaskets and the brake
booster tube from the upper intake manifold.
(e) Remove the 2 bolts and the EVAP pipe from the intake
manifold.
(f) Disconnect the fuel return hose from the fuel pressure
regulator.
(g) Remove the 3 bolts holding the fuel return hose from the
lower intake manifold.
(h) Remove the fuel pressure regulator, the fuel pressure
pulsation damper and the 2 gaskets.
(i) Remove the bolt and the rear fuel pipe.
(j) Remove the 2 delivery pipes and the 8 injectors (See
page
SF-22).

A05516
A05517
A05564
EM-38
- ENGINE MECHANICALCYLINDER HEAD
1611 Author
: Date
:
2004 LAND CRUISER (RM1071U)
14. REMOVE WATER INLET AND INLET HOUSING AS-
SEMBLY (See page CO-6)
15. REMOVE FRONT WATER BYPASS JOINT
Remove the 4 nuts, the water bypass joint and the 2 gaskets.
16. REMOVE REAR WATER BYPASS JOINT
Remove the 4 nuts, the water bypass joint and the 2 gaskets.
17. REMOVE ENGINE HANGERS
18. REMOVE OIL DIPSTICK AND GUIDE FOR A/T
19. REMOVE CYLINDER HEAD COVERS
Remove the 18 bolts, the 18 seal washers, the cylinder head
cover and gasket. Remove the 2 cylinder head covers.
20. IF NECESSARY, REMOVE SEMI-CIRCULAR PLUGS
AND CAMSHAFT HOUSING PLUGS
21. REMOVE 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.

A04456
No. 2 Idler
Pulley Bolt
Crankshaft
Pulley BoltTiming
Mark
A04467Service Bolt
A04468
A04469
8101241
14161862
19
2021
22
1315175
79113
- ENGINE MECHANICALCYLINDER HEAD
EM-39
1612 Author
: Date
:
2004 LAND CRUISER (RM1071U)
(a) Check the crankshaft pulley position.
Check that the timing mark of the crankshaft pulley is
aligned 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) Remove the RH camshafts.
(1) Move a service bolt of the sub-gear upward by turn-
ing the hexagon shaped port of the exhaust cam-
shaft with a wrench.
(2) Secure the sub-gear to the main gear with a service
bolt.
Recommended service bolt:
Thread diameter6 mm
Thread pitch1.0 mm
Bolt length16 - 20 mm
HINT:
When removing the camshafts, make sure that the torsional
spring force of the sub-gear is eliminated by the above opera-
tion.
(3) Set the timing mark (1 dot mark) of the camshaft
main gear at approx. 10° angle by turning the hexa-
gon wrench head portion of the exhaust camshaft
with a wrench.
(4) Uniformly loosen and remove the 22 bearing cap
bolts a little at a time for several times in the se-
quence shown.
(5) Remove the oil feed pipe, 9 bearing caps, cam shaft
timing oil control valve and camshafts.